Document vyaa4k20MYyLRbkL0qpoNv4b6

ABD00242736 VCM UNLOADING OPERATING MANUAL ABERDEEN CHEMICAL PLANT ABERDEEN, MISSISSIPPI NOVEMBER 4, 1982 Work By: '/I tWCjjM. P. Bl^tk:fkcwell Operations Engineer Revised By: J*. & Approved By L. D. Honeycutt Yard Supervisor Approved By: P. E. Markey Vinyl Operation Supt. ABD00242737 VCM UNLOADING OPERATING MANUAL ABERDEEN PVC PLANT ' TABLE OF CONTENTS I. INTRODUCTION Page No. A. Operator Responsibilities ...................................................................................... 1 B. General Process Description............................................................................................ 3 II. OPERATING PROCEDURES A. Railcar Hookup................................................................... 10 B. Unloading Railcars .......................................................................................................... 17 C. Recovering Vapor From Railcars ............................................................................. 22 D. Unhooking Railcars .................................. ............................. .... 24 E. Troubleshooting and Miscellaneous Operating Procedures 1. Liquid in the Compressor Suction.................................................................. 29 2. High Pressure on the Sphere or Bullets (or Evacuation) ... 29 3. Evacuating a Compressor for Maintenance.......................................; . 30 4. Lack of Liquid Flow in Sight Glass ............................................................. 33 5. Tank Car Excess Flow Valve Closing.............................................................. 34 6. Evacuating the VCM Vapor Line Knockout Pot and Recycle Pump for Maintenance.......................................................................................... 35 III. EQUIPMENT INDEX ........................................................................................... ............................ 37 IV. SAFETY EQUIPMENT AND SYSTEMS................................................................................................40 V. EQUIPMENT ENTRY PROCEDURES ........................................................................................... 44 VI. APPENDIX A. Valve Setup Checklist B. Checklist for Testing Auto Valves C. Plant Emergency Plan D. P & I Diagram E. Photographs F. Sample Railcar Placard ABD00242738 VCM UNLOADING OPERATION MANUAL ABERDEEN PVC PLANT INTRODUCTION A. Operator Responsibilities The purpose of the VCM Tank Farm is to safely unload and store Vinyl Chloride Monomer (VCM). VCM is brought into the plant in tankcars. It is the main raw material used in making the plant's major product, polyvinyl chloride (PVC). VCM is a colorless sweet-smelling gas at atmospheric pressure that is stored and transferred as a liquid at moderate pressure (30-70 psig). The yard department is responsible for the-offloading of VCM tankcars and the related transfer equipment. The yard operator helps fulfill the tankfarm's purpose by making sure that the VCM is safely unloaded without endangering his fellow workers or equipment. The operator is able to attain his goals in safety, job performance and efficient operation through a training period, on-the-job experience, and passing written and field examinations. The operator fulfills his responsi bilities by: 1. Demonstrating understanding of how his equipment functions. 2. Being able to explain what role each piece of equipment plays in the process. 3. Keeping a close and regular check on equipment. 4. Being able to demonstrate troubleshooting and corrective measures. 5. Keeping his area of responsibility safe and clean. 6. Keeping complete and accurate records. 7. Reporting equipment problems promptly and writing maintenance work orders as needed. ABD00242739 VCM Unloading Operating Manual Page.2 I. INTRODUCTION (Cont.) A. Operator Responsibilites (Cont.) This operating manual will cover the normal responsibilities and duties of the yard operator when unloading VCM railcars. Each phase of the unloading procedure will be covered. In addition to normal operating procedures it will also discuss operations under abnormal conditions. The operator must be prepared to meet these situations with temporary measures until the abnormal condition is corrected or ceases to exist. Safety takes second place to no plant activity. The safety of the plant personnel and equipment is to be carefully considered before any job is started. The Conoco safety slogan is "Our work is never so urgent or important that we cannot take time to do it safely". Safety on the job must be our first and most important consideration. When we do a good job of planning our work with safety in mind, we are less likely to suffer injury or cause an accident. This allows us to meet our plant goal of employees going home unhurt. ABD00242740 VCM Unloading Operating Manual Page 3 I. INTRODUCTION (Cont.) B. General Process Description VCM tankcars are brought into the plant from various VCM plants through out the United States. Most of the VCM that comes into this plant comes from Conoco's VCM Plant in Lake Charles, Louisiana. VCM also occa sionally comes from PPG in Lake Charles, B. F. Goodrich in Calvert City, Kentucky, or from Uniroyal in Geismar, Louisiana. A VCM Tankcar typically holds 175,000 pounds of VCM (about 23,000 gallons of iiquid). If for some reason an inbound VCM car's gross weight is less than 255,000 pounds, the car must be reweighed and spotted on the west track until billing weights are verified. The cars are shipped to Aberdeen and stored on the Monroe lead until they are brought into the plant. Only the Monroe lead or new VCM spur can be used to store VCM railcars.. This is a safety precaution so that all the VCM cars are kept in one. general area. The railroad crew is responsible for bringing the VCM cars into the plant and "spotting" them at the VCM transfer stations that are on the platform at the VCM tank farm. This is usually done once per day except on weekends or holidays. A maximum of ten tankcars can presently be brought into the tank farm. The tank farm has eight transfer (unloading) stations. The platform is located between two sets of railroad tracks such that there are four transfer stations on each side. These are referred to by name as Spot No. 1, Spot No. 2, Spot No. 3, and Spot No. 4, from north to south, respectively. A maximum of two tankcars can be hooked up at each spot. Once the railcars have been "spotted", it is the yard department's responsibility to unload the VCM into T-601 which is commonly called the ^BB00242741- VCM Unloading Operating Manual Page 4 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) ."sphere". This is done using the five Corken compressors at the tank farm. They are commonly referred to as Compressor No. 1, Compressor No. 2, Compressor No.3, Compressor No. 4, and Compressor No. 5, from north to south, respectively. Compressors No. 3 and No. 5 combined have about the same capacity as either Compressor No. 1, No. 2, or No. 4. The tankcars are connected to the compressor piping and the sphere piping with flexible hoses. The compressors pull vapor from the top of the sphere and compress it into the tankcars, forcing liquid out of the cars through a stand pipe, into the bottom of the sphere. Each tankcar has three valved connections in the dome of the car (two liquid lines and one vapor line). The liquid lines are 2" lines and point toward each end of the tankcar. The vapor line is a 1^" line and points toward the side of the car. Refer to the photograph in the Appendix. Only one liquid line is usually hooked up on a car because the car does not unload significantly faster with two lines and it takes longer to hook up the car. Both liquid lines have to be hooked up on some type of cars (ACFX and PPGX cars) because the excess flow valves are set to close at lower rates than our normal unloading rate of 65-95 gpm. The operator can tell when all the liquid has been unloaded from a car by watching the sight glass in the liquid transfer line. When the tankcar has been emptied, the 4-way valves on the compressor are reversed such that the compressor evacuates vapor from the car and discharges it into the top of the sphere. When the specified amount of vapor is removed from the tankcar, the compressors are shut down and the transfer lines VCM Unloading Operating Manual Page 5 ABD00242742 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) are evacuated. This must be done because of EPA (Environmental Protec tion Agency) regulations concerning the release of VCM vapor to the atmosphere. Then the transfer line can be unhooked and the cars are sent back to the respective VCM plant for reloading. All outbound VCM cars are to be weighed. Cars containing a heel greater than 600 pounds should be set aside for additional unloading. The plant can lose considerable amounts of VCM on heavy outbound cars, which can drastically impact on our plant*s cost effectiveness. There is a big difference in winter and summer operation of the tank farm. The primary reason is probably because the vessels are uninsulated and the transfer lines are lengthy and are exposed to ambient tempera tures along their entire run. The vapor pressure drops in the vessels and the tankcars as the temperature drops, making it harder to unload in. cold weather because there is less VCM pressure to move the liquid through the pipes. Thus, unloading conditions can also vary from day to night and when rapid changes in weather occur. During the summer, eight tankcars can be hooked up at one time and unloaded with four or five compressors. Also, the tankcars will usually start unloading as soon as the valves on the liquid lines are opened. During winter conditions (ambient temperature approximately 40F or less), it is harder to start the VCM liquid unloading and only four tankcars can be unloaded at a time, with four or five compressors. If the weather gets extremely cold, it may take four compressors to unload only two or even one car, but this has not happened since the -Aftft00242743 VCM Unloading Operating Manual Page 6 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) system has been revised and vapor from the sphere is used. The volume ..of VCM kept in the sphere is usually large enough that sufficient vapor is available for the compressors. When the bullets were used, there was not enough vapor available and the tankcars unloaded very, very slowly, if at all. Other equipment at the tank farm includes the bullets, T-201 (west) and T-202 (east). These are not used for unloading VCM, even though each one presently contains a small amount of liquid VCM. They are piped up to take inerts from the recovered vinyl receivers if the incinerator should be down for an extended period of time. The transfer pumps on the bullets (Conoco Nos. 72-211 & 72-218) and the sphere (Conoco Nos. 72-217 & 72-270) are the responsibility of the vinyl department. The sphere transfer pumps send liquid VCM through a 4" line to the old and new reactor modules where, it is charged into reactors and made into PVC. The bullet transfer pumps are not used at the present time. The emission recovery system knockout pot is also located at the tank farm, northwest of the compressor shed. The emission recovery system.is located in the vinyl department old reactor module and is designed to collect and contain miscellaneous VCM emissions. It runs continuously. The knockout pot is connected to it via a 2" line that runs to the tank farm. A 15" Hg. vacuum should be maintained on this line at all times. This line is used to evacuate the VCM vapors from the transfer lines prior to unhooking cars. The knockout pot is the responsibility of the VCM Unloading Operating Manual Page 7 ABD00242744 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) vinyl department, but the yard operator should be familiar with the purpose of it. The knockout pot collects VCM vents from the following: a. Double Mechanical Seals on the sphere and bullets transfer pumps- Used by vinyl to bleed VCM from the seals when maintenance is required on the pumps. b. Corken Compressor Packings- The pot recovers vapor that leaks through the compressor packing into the distance piece.' The vapor goes through a rotameter on each compressor into the pot. The valve above the rotameter should always be open when the compressor is running. The knockout pot must always have a slightly positive pressure on it or oil can be sucked out of the bottom of the compressors through the packing around the piston rods. This is the reason for the back pressure control valve on the knockout pot. c. Corken Compressor Relief Valve Discharges- The relief valve dis charges are piped to the knockout pot through a locked open valve. d. Corken Compressor Liquid Traps- Liquid caught in the traps is drained to the knockout pot through the 1" Jamesbury valves on the traps. Opening the 1" valve should let the liquid flow into the knockout pot and then it is recovered to the emission recovery system. e. VCM Sphere and Bullet Recovery- The vessels can be recovered through the knockout pot. A procedure will be given for this in the opera ting procedures section. f. Sphere Liquid Lines Relief Valve Discharges- The three liquid lines ABD00242745 VCM Unloading Operating Manual Page 8 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) under the sphere have relief valves that discharge into a 1" line ., that goes to the knockout pot. The 1" valve on the line south of the compressor shed is locked open. The line runs into the header at the west side of the knockout pot, where the main 2" valve is also locked open. g. Compressor No. 1 Liquid Line Relief Valve Discharge- This relief valve is piped up to the compressor relief valve header through a locked open valve. h. Vapor Line Knockout Pot Relief Valve Discharge- This knockout pot is equipped with a relief valve whose discharge is piped through a locked open valve into the compressor relief valve header. The compressor relief valve header is connected to the emission recovery system knockout pot. i. VCM Recycle Pump Relief Valve Discharge- The VCM recycle pump located below the liquid line knockout pot is equipped with a relief valve which is piped up to the compressor relief valve header. A second knockout pot, called the vapor line knockout pot, is located just north of the emission recovery system knockout pot. The purpose of the vapor line knockout pot is to collect liquid VCM that may have, collected in the main vapor line and prevent this liquid from slugging the compressors. A VCM recycle pump is located below this knockout pot and is used to pump the contents of the pot to the sphere. The pump is started and stopped by two level switches in the pot. VCM Unloading Operating Manual Page 9 ABD00242746 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) Complete and accurate records must be kept on VCM unloading. These are necessary for accounting purposes and for communication between, shifts. A VCM Unloading Card must be filled out and turned in to. the accounting group for each car unloaded. Records are also kept in the yard scale-house on which cars were unloaded, when they started, when they were put on vapor, and when they were unhooked. A valve setup checklist also must be filled out by the yard opera tor when hooking up cars and starting unloading. Copies are to be kept on file by the yard supervisor. A copy of the checklist is included in the Appendix. The automatic valves under the sphere are tested every Wednesday. morning. The checklist used to record the results of this testing is shown in the Appendix. Copies of this checklist are to be kept on file by the yard supervisor. This testing must be coordinated with the vinyl panel operators so that the valves are not closed during VCM transfer to the reactor units. ABD00242747 VCM.Unloading Operating Manual Page 10 II. OPERATING PROCEDURES A. Railcar Hookup After VCM cars are brought into the plant, the yard operator "hooks up" each car by connecting transfer hoses to it. Vapor can then be trans ported into the car and the liquid VCM can be sent into the sphere. In the summer, two cars can be hooked up at each transfer station for unloading. During winter operation or when a rapid change in the weather is anticipated during unloading, only one car can be unloaded from each transfer station. Fresh air masks must be worn under the compressor shed while opening or closing the railcar dome, or while connecting and disconnecting the transfer hoses. Gloves must be worn while handling the nipples and the transfer hoses. VCM cars are not to be hooked up during an electrical storm. Equipment Required 1. Fresh Air Mask 2. 1 1/2" Teflon Tape 3. 0-rings for camlock couplings and Weco fittings (if needed) 4. Gloves Procedure 1. Get a fresh air mask and a roll of 1 1/2" Teflon tape, from the yard scale house. Also get "0" rings that are needed to replace the ones at the tank farm. (Note that there are two types of 0-rings. The larger ones are for the Weco fittings, while the smaller ones are used with the camlock couplings.) Inspect the "0" rings individ ually for cracks and nicks. VCM Unloading Operating Manual Page 11 ABD00242748 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont,) Procedure (Cont.) 2. Raise the blue metal flag located on the railroad track south of the roadway. This flag states "Stop! Tankcar Connected." This procedure is necessary to isolate the eight unloading stations and notify railroad personnel that VCM unloading is taking place. 3. Engage the derailer located near the blue flag. This will prevent railcars from entering the tank farm area when unloading is taking place. 4. Check the railcar chocks and handbrake and ground the railcar. Make sure that the chocks are in good condition and are against the railcar wheels. Manually check the handbrake to make sure it is tight. Inspect the grounding cables to ensure that they are intact and in good working condition. Bond each car to the ground rod by attach ing the grounding clamp from the north side of the ladder to the north vertical siderail of the ladder. This prevents static accumulation during unloading and eliminates dangerous sparking which could ignite any VCM leaks. It also prevents loss of the ground clamp if it is left connected during switching. Should one of the grounding clamps or cables be damaged, use the backup cable located on the south liquid boom arms at each spot except Spot No. 1 which has no backup cables. 5. Drain the water from the breathing air filter if necessary. (The filter is located between the rail tracks). 6. Visually check the valves under the sphere to make sure they are set up for unloading. The 4" valve on the vapor line and the 6" valve ABD00242749 VCM Unloading Operating Manual Page 12 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) under the sphere on the liquid line to the sphere must be open, (both valves are actuated valves). 7. Record the sphere level on the checklist (see checklist in Appen dix). Turn the handle on the gauge to move the tape, then take the reading. If the tape does not bounce, notify the yard supervisor. The maximum allowable'sphere level is 38 feet. To unload 4 tankcars the level must be below 32 feet - 3 inches (27 feet - 0 inches for 8 tankcars). 8. Climb the stairs to the unloading platform. If the stairs are wet or icy, be especially careful. Always be sure to use the handrail. 9. Go to the station you want to unload from, loosen the locks on the walkramp, and use your foot to push the ramp onto the car dome. The ramp will not operate if it is not in the middle of the platform opening. Adjust the height and length of the ramp and lock the ramp into place. Watch for pinch points when positioning the ramp and do not put any unnecessary strain on your back. 10. Unlatch the vapor and liquid line(s) and swing each line over the railcar dome area. Be careful not to let the lines swing back and catch your arm or hands. (The vapor line is the IJ5" line). 11. Remove the nipples from the holders and peel off the old Teflon tape. Inspect the threads and retape them with new tape up to 2" from the end of the threads. If the threads are worn,, write a work order to replace the old nipples with new ones. VCM Unloading Operating Manual Page 13 ABD00242750 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 12. Remove the pipewrench from the holder and fasten it on one nipple, Then carry the pipewrench and nipples to the dome area of the car. Be careful not to drop the nipple and damage the threads, 13. Put on the fresh air mask and tighten it. Test the face seal by blocking the hose with one hand while trying to breathe in. If . it leaks, adjust the-r straps or facepiece. Make sure you have a good face seal. 14. Purge the air line of any water that may be in the line. Connect the fresh air mask to the fresh air hose that is on the transfer line booms. 15. Break the domelid seal with the pipewrench and slide the latching bar so that the lid can be raised. Open the domelid and push, it all the way back so that it cannot close. Be careful to use proper lifting procedures when raising the lid. 16. Visually check inside the dome area for leaks. Leaks will be indicated by condensation or icing around the valves and fittings. 17. Test the valves to make sure they are closed by pushing the valve handles against the closed stop. 18. Adjust the pipewrench to fit the railcar valve plugs and remove the plugs. Be alert to the fact that the wrench could slip and trap your hand or fingers against the dome. Also do not stand in the direction of the valve opening in case a valve is leaking and VCM spews out. A ABD00242751 VCM Unloading Operating Manual Page 14 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 19. Push the port hole covers aside and screw the nipples into the valve opening until they are hand tight. Then tighten the nipples with the pipewrench. Be careful not to let the wrench slip. The nipples must be very tight or they will leak. Double check them after installing. 20. Close the bleed off valves on the end of the transfer line booms. Make sure they are fully closed so that VCM will not leak to the atmosphere. 21. Unhook the flexlines and camlock couplings or Weco fittings from the holders on the booms. Be careful to minimize bending and twisting the flexlines during hookup. Excessive bending of the flexlines causes early failure of the lines. Visually inspect the flexlines for small holes or extremely worn areas of the armored weave. If a flexline is punctured, badly twisted or damaged, or in your judgment has a likely potential for failure during operation, contact maintenance and have the hose replaced. 22. Inspect the "0" rings individually and install them in the coupling slots (for the camlock couplings). For stations with the Weco fittings, the "0" rings fit in a slot on the nipple. The "0" ring must be evenly seated to prevent leaks. "0" rings with cuts or nicks should be discarded. 23. For stations with camlock couplings, press the coupling against the nipple flange and tighten the bolts hand tight. Check the VCM Unloading Operating Manual Page 15 ABD00242752 IX. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) alignment of the "0" ring against the flange and the coupling to make sure there is a good seal. M0M rings that are pinched or crook ed will cause leaks. When the "0M ring is seated properly, evenly tighten the bolts with the pipewrench. (Note: Do not beat on the flanges with the pipewrench.) For stations with Weco-fittings, press the Weco union attached to the flex hose against the nipple inserted in the railcar. Check the alignment of the "0" ring to make sure there is a good seal. Com pletely tighten the Weco hammerlock to prevent leakage. 24. Check to make sure that the valve on the transfer line closest to the railcar dome is closed (it should be closed from the previous unhook ing). Slowly pull the handle of each railcar valve down to open it. Opening the valves too fast can cause an undesirable surge of pressure. Check for leaks around each coupling or bleed off valve as the railcar valves are opened. . 25. Slowly open the liquid valve(s) on the end of the booms. Then open the vapor valve at the end of the boom. Make sure that the valves are fully opened or flow will be restricted. 26. Recheck the valves on each transfer line to make sure they are open. The railcar dome valve and both tranfer line valves must be open. The bleed valve must be closed. Initial the checklist to show that the valves are open. 27. Inspect the flex hose for leaks. Contact maintenance to replace any leaking flex hoses. (Note: The line must be disconnected using ABD00242753 VCM Unloading Operating Manual Page 16 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) proper procedures prior to replacing. The procedure is on page 24 - "Unhooking Railcars"). 28. Disconnect the fresh air mask and check the pressure gauges at the platform on the vapor and liquid lines and make sure that they are showing pressure. Lack of pressure may indicate a leak, a plug or a closed valve. 29. Hookup additional railcars using steps 9-27. VCM Unloading Operating Manual Page 17 ABD00242754 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars After the VCM cars at the tank farm are hooked up, the cars are unload ed using the Corken compressors. The compressors take vapor from the . top of the sphere and compress it into the tank cars, forcing the liquid in the cars to flow into the bottom of the sphere. It usually takes 4-6 hours to unload the liquid VCM from a tankcar. It is very important for the valves on the compressors to be set up "U * correctly or the compressor will dead-head. Running the compressors in a dead-headed condition will raise the compressors** relief valves, and force VCM into the emission recovery knockout pot T-201. A pressure switch on T-201 will shut down all compressors if the pressure in the pot reaches 100 psig. Equipment Required 1. Fresh Air Mask. Procedure 1. After hooking up the cars, carefully come down the stairs from the unloading platform, using the handrails. Check the valves that are between the railroad tracks going to each unloading station, which is to be used for unloading cars. All the valves should normally be open. Initial the checklist if the valves are open. If any of the valves are closed, do not startup any compressors going to that unloading station. 2. Go to the compressor shed and connect the fresh air mask to the fresh air hose. Put on the mask. Use the proper procedure for the fresh air mask as described earlier. ABD00242755 VCM Unloading Operating Manual Page 18 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Cont.) Procedure (Cont.) 3. Open the main liquid valve on the west side of the compressor shed on the sphere liquid line (it should have been closed prior to unhooking previous cars). Initial the checklist appropriately after opening the valve. 4. Visually inspect each liquid unloading line from where they come out of the ground on the east side of the compressor shed through the valves near the ground, through the sight glasses, across the compressor shed, and through the valves above the liquid header on the west side of the shed. All valves must be open from each spot being unloaded from. During summer operations, flow may be observed in the sight glass after opening the main liquid valve. This is due to the vapor pressure in the car forcing liquid to start unloading. Initial the checklist after making sure that the valves are open (Checklist Item: Valves Under Sight Glasses, etc.). 5. Open the main vapor valve at the west side of the compressor shed on the sphere vapor line (it should have been closed prior to unhook ing previous cars). Initial the checklist appropriately after opening the valve. 6. Open the vapor line knockout pot inlet and outlet valves to allow vapor to flow through the knockout pot. These valves are located near the main vapor valve. Close the vapor header block valve located between the knockout pot inlet and outlet valves. 7. Visually trace the vapor lines going from the sphere vapor line, through the manual valves to the 4-way valve on each compressor. The manual valve must be open for each compressor that will be run. VCM Unloading Operating Manual Page 19 ABD00242756 XI; OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Cont.) Procedure (Cont.) Initial the checklist after checking the vapor valve for each com pressor. 8. Check the level of the VCM in the vapor line knockout pot by observing the sight glass located on the east side of the pot. The level should be below the pot's low level switch before unloading is started. The level in the pot is automatically controlled by high and low level switches. Should the instruments malfunction and the level be above the low level switch, notify the yard supervisor and proceed to drain the pot manually. Do this by placing the VCM recycle pump switch in the "hand" position. This switch is located on a panel on the south side . of the knockout pot. The recycle pump will pump the contents of the pot to the sphere. When the level in the pot has lowered to the low . level switch, place the pump switch back in the "auto" position. 9. Turn the handle of each 4-way valve so that the handle is in the vertical position. This sets up the compressor to pull from the sphere and discharge into the tank cars. (NOTE: The handles can be installed in the opposite direction. If maintenance works on a 4-way valve, check the arrows on the valve and make sure the flow is from the sphere to the tankcars when the valve handle is vertical. This must be checked before signing off the work order.) 10. Check the suction pressure of each compressor. It should read the same as the sphere pressure. If the pressure is 0 psig, the liquid trap may be full of liquid which closes the high level shutoff valve in the trap and will not allow any flow to the compressor. The trap can be drained ABD00242757 VCM Unloading Operating Manual Page 20 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Con.t) .. Procedure (Cont.) by opening the Jamesbury valve that goes to the emission recovery knockout pot by the compressor shed. When the liquid is drained'off, the pressure will rise on the suction (as the shutoff valve opens). 11. When the suction of each compressor is set up correctly, visually trace the vapor discharge lines for each compressor. When all of the compressors are to be -run. Compressors No, 3 and No. 5 should dis charge to the No. 3 transfer station, Compressor No. 2 should dis charge to No. 2 transfer station. Compressor No. 4 should discharge to the No. 4 transfer station, and Compressor No. 1 should discharge to the No. 1 transfer station. When one or more compressors are not to be run, or if fewer than four railcars are to be unloaded, it is best to setup the compressors on common discharge by opening the four valves on the No. 5 compressor header. This allows all the compres sors to be set up on one common header. Check the valves on the line from the No. 5 compressor to made sure they are set up correctly and be sure to check the jumper lines that connect the lines going to the four spots. Finally, check the four vapor valves near the ground going to the four transfer stations. The valve to each transfer station that is to be unloaded from must be open. Initial the checklist after making sure the appropriate valves are open. 12. When all the lines have been traced for each compressor, push the start buttons for the compressors to be run. 13. Check the oil pressure on each compressor. It must read between 10-20 psig. VCM Unloading Operating Manual Page 21 ABD00242758 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Cont.) Procedure (Cont.) 14. Check the discharge pressure on each compressor. If it is under 100 psig, go to the sight glasses and watch for liquid flow. If the discharge pressure is above 110 psig, one of the valves between the compressor and the tank car is closed. Shut off the compressor and retrace the piping until the valve is opened. 15. Check for liquid flow to the sphere in all the sight glasses. Lack of flow may indicate a closed valve between the tank car and the sphere. 16. Check to see that the Jamesbury valves on the compressor suction liquid traps are closed. 17. Take off the fresh air mask, disconnect it, and roll up the hose. 18. Record the identification numbers of the railcars being unloaded and log into log book. ---t---- ----- -- ADD00242759 - - VCM Unloading Operating Manual Page 22 II. OPERATING PROCEDURES (Cont.) C. Recovering Vapor from Railcars When the liquid VCM has been unloaded from the VCM tank cars, the Corken compressors are used to remove most of the remaining VCM vapor from the car. The compressor is set up to take vapor from the tank car and send it back to the sphere. The railcars are pulled down to about 6-8 psig. If they are recovered to less than 6 psig it causes problems at the VCM plants, because the car may be below atmospheric pressure and pull air into the car-. If the cars are not recovered to less than 8 psig, we are charged for some of the VCM which is left in the car. It normally takes 1-2 hours to recover vapor from the railcars. Equipment Required 1. Fresh Air Mask. Procedure 1, Go to the tank farm and check the sight glasses to make sure the liquid has blown out of the railcars. NOTE: If one of the cars blows out before the others, hook up and put on the fresh air mask and open the four valves from the No. 5 compressor header (this sets up all the compressors on one common header). Then close the valve near the ground on the vapor transfer line at the east side of the compressor shed for the transfer station which has blown out. This will cause the cars that have not blown out to empty faster. After the cars have blown out, be sure to reopen any valves on the vapor transfer lines that were closed. If there are 2 cars hooked up on any of the transfer stations, both cars will have to be checked to see if they have blown out. Use the follow ing procedure: (Assume that railcar A and railcar B are hooked up VCM Unloading Operating Manual Page 23 ABD00242760 II. OPERATING PROCEDURES (Cont.) C. Recovering Vapor From Railcars (Cont.) Procedure (Cont.) on the same transfer station and that the sight glass for that transfer station shows vapor flow). A. Go to the dome of railcar A and close the liquid valve(s). This allows you to check the sight glass and see if the liquid has blown out of railcar B. B. Go to the sight glassy and check for liquid blowing through the line. If liquid flow shows in the sight glass, railcar B has not blown out. Finish unloading it by closing the vapor valve on railcar A and setting up the compressors on a common header as mentioned in. the first part of this procedure. C. When the sight glass shows that railcar B has blown out, go back to the platform and open the liquid valve(s) on railcar A. D. Next, close the liquid valve(s) on railcar B to make sure that railcar A has blown out. E. Check the sight glass as in step B (Above). If liquid flow shows in the sight glass, railcar A was not blown out and must be unloaded. Close the vapor valve on railcar B and set up the compressors on a common header to unload railcar A. F. When the sight glass shows that railcar A has blown out, re-open the liquid valve(s) on railcar B. G. After all the cars have blown out, reopen any valve that you closed to check or unload the railcars. 2. Put on the fresh air mask, check for face seal, and connect it to the fresh air hose. ABD00242761 VCM Unloading Operating Manual Page 24 II. OPERATING PROCEDURES (Cont.) C. Recovering Vapor from Railcars (Cont.) Procedure (Cont.) 3. Open the four valves on the No. 5 compressor header so that all the compressors are on one comon header. 4. Reverse all the 4-way valves so that the handles are in the horizon tal position. 5. Check the compressor discharge pressures to make sure the compres sors are not dead headed (pressure should be 70-100 psig). 6. Take off the fresh air mask, disconnect it and roll up the hose. 7. Record in the logbook the time that the cars were put on vapor. D. Unhooking Railcars When the VCM railcars at the tank farm have been unloaded arid evacuated to the specified pressure, the compressors will be automatically shut off by the low pressure switches. Before the cars can be unhooked, the amount of VCM vapor in the transfer hose must be reduced to 0.13 cubic feet of VCM vapor (at 20 C and 29.92 in. Hg) to comply with EPA regula tions. To meet this requirement, the lines must be evacuated to a 10" Hg vacuum. Then the lines can be unhooked and the cars can be sent out of the plant. Fresh air masks must be worn under the compressor shed or while connect ing the transfer hoses. Gloves must be worn while handling the nipples and the transfer hoses. VCM cars are not to be unhooked during an elec trical storm. Equipment Required 1. Fresh Air Mask 2. Gloves VCM Unloading Operating Manual Page 25 ABD00242762 XX. OPERATING PROCEDURES (Cont.) D. Unhooking Railcars (Cont.) Procedure 1. Go to the tank farm and climb the platform stairs. Be especially careful if the stairs are wet or icy and be sure to use the hand rail. 2. Check the pressure on each transfer station according to the gauges on the platform. Make sure that the car(s) at each transfer station have been pulled down'to 6-8 psig. NOTE: If one of the transfer stations has reached the proper evacu ation pressure before the others, close the valves at the platform for that transfer station. Since the compressors are on one common header, this will allow the other transfer station(s) to evacuate faster. When all the transfer stations have been properly evacu ated, reopen the valves on the transfer lines which you closed. 3. Climb down from the platform (carefully), hook up the air mask to the hose at the compressor shed, and put on the mask. 4. Turn off the compressors. 5. Close the 4" main vapor valve from the sphere and the 6" main liquid valve to the sphere that are on the west side of the compressor shed, 6. Check the pressure gauge on the line to the emission recovery system. (Gauge is at the southwest corner of compressor shed.) It must read at least 10" Hg vacuum. Open the four manual valves that evacuate the transfer lines to the emission recovery system. NOTE: If there is not at least 10" Hg vacuum on the line, notify the vinyl control room. It is the vinyl department's responsibility to maintain at least 10" Hg vacuum on the line. ABD00242763 VCM Unloading Operating Manual Page 26 II. OPERATING PROCEDURES (Cont.) D. Unhooking Railcars (Con.t) Procedure (Cont.) 7. Immediately after opening the four manual evacuation valves, care fully climb the stairs to the unloading platform, hook up and put bn the fresh air mask, check for face seal, and close the valves in the railcar dome on each car that was unloaded (you will have to unhook and reconnect the fresh air mask at each station). 8. Open the actuated valves that evacuate the transfer lines to the emission recovery system by opening the switch at each transfer station.- (Write work orders for any valves that do not open or close correctly.) 9. When the pressure gauge at the transfer station reads 10" Hg vacuum or less, put on the fresh air mask and close the valve.on the trans fer line that is closest to the railcar dome. The pressure gauges should be maintained in good working condition or be replaced. The stainless steel flex hose is now valved off at 10" Hg vacuum or less, which complies with EPA regulations. 10. Open the V vacuum breaker bleed valve at the end of the transfer line boom. 11. Loosen the bolts on the coupling with the pipe wrench and disconnect the coupling. 12. Take the "0" ring out of the coupling and inspect it. Discard it if it has any nicks or cracks on it. Close the vacuum breaker bleed valve and hang the "0" ring around it. 13. Connect the transfer line to the boom and swing it out of the way. 14. Unscrew the nipples from the railcar valve opening with the pipewrench. Remove them from the dome and cover the portholes. VCM Unloading Operating Manual Page 27 ABD00242764 XX. OPERATING PROCEDURES (Cont.) D. Unhooking Railcars (Cont.) ' Procedure (Cont.) Be careful not to.let the pipewrench slip and trap your hands or . fingers against the railcar. 15. Adjust the pipewrench to fit the. railcar valve plugs and screw them tightly into the valve opening. Once again, do not let the wrench slip while tightening the plugs. 16. Put the nipples and pipewrench on the transfer station walk ramp and close the railcar dome lid. Be careful not to let the lid trap your hands or fingers. Slide the latching bar shut to hold the lid closed. 17. Unhook the fresh air mask and take the pipewrench and nipples back to the main platform. Place them in the racks provided for them. Be careful not to drop the nipples or damage the threads. 18. Turn off the switch to close the actuated valves that evacuate the transfer lines to the emission recovery system. 19. Latch the transfer line booms to the platform. Be careful not to let them pinch your arms or hands. Do not bend or twist the flex- lines excessively. This can cause early failure of the flexlines. 20. Loosen the locks on the walk ramp and pull it away from the tank car. Lock it after raising it into the vertical position. 21. Repeat steps 9-20 to unhook the other railcars. 22. After unhooking all the railcars, climb down the steps from the platform. Do Not leave the fresh air mask on the platform. Take it back to the yard scale house with you and place it in the proper receptacle for cleaning at the end of your shift. 23. Unhook the ground cable from the unloading station. ABD00242765 VCM Unloading Operating Manual Page 28 II. OPERATING PROCEDURES (Cont.) D. Unhooking Railcars (Cont.) Procedure (Cont.) 24. Turn the placards.on the railcar over so that they read "Empty." These placards must be present on both sides and both ends of each car. A sample of the railcar placards is attached in this manual. 25. Close the manual valves on the 1" lines from the VCM transfer lines to the emission recovery header (under northeast corner of compres sor shed). These must be manually blocked in to prevent air or VCM leaks into the emission recovery system and to prevent VCM leakage through the automatic valves during railcar unloading.. 26. Lower the blue flag to show that tank cars are no longer connected. 27. Disengage the derailer located south of the roadway. 28. Go to the sphere and record the level. Record this level and other information about unhooking the car in the logbooks in the yard scalehouse. VCM Unloading Operating Manual page 29 ABD00242766 XI. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures This section describes various problems that occasionally occur in con-, nection with the Corken compressors and unloading the VCM tank cars. The standard operating procedure for solving each problem is given after the problem description. Normal rules concerning the use of safety equipment apply in all of these situations. Fresh air masks must be .. worn under the compressor shed. 1. Liquid in the Compressor Suction The symptoms of this problem and the solution are given in the operating procedures on unloading railcars, step No. 8. 2. High Pressure on the Sphere or Bullets (or Evacuation) Occasionally, the pressure on the bullets or the sphere needs to be reduced. This can be done by opening the appropriate valves and letting the emission recovery system pull on the vessel(s). A. To pull vapor from the sphere: a. Close the five valves on the west side of the compressor shed that are on the sphere vapor line. b. Open the main 4" valve on the sphere vapor line. c. Open the valve on the bullets vapor line that connects to the sphere vapor line. d. Open the 2" valve on the line that connects the bullets vapor line to the emission recovery knockout pot at the northwest corner of the compressor shed. This is the same line that the compressor relief valves discharge into. The knockout pot is set up to relieve any pressure over 3 psig to the emission recovery system. ABD00242767 VCM Unloading Operating Manual Page 30 II. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 2. High Pressure on the Sphere or Bullets (or Evacuation) (Cont.) B. To pull vapor from the bullets: a. Open the valves at the bullets on the line that goes to the sphere vapor line from the bullets. b. Follow step (d) in the procedure for pulling vapor from the sphere. C. To evacuate the sphere or bullets: Considerable planning and preparation must be done prior to attempting this procedure. However, the following concept should be utilized. a. Follow the above procedure for pulling vapor from the appro priate vessel. b. Close the manual 2" valve on the line from the Corkeh com pressor distance pieces to the emission recovery knockout pot. This will prevent the oil from being pulled out of the compressors when the knockout pot is pulled to below atmos pheric pressure. c. Open the bypass valve for the pressure control valve that is south of the knockout pot. This will allow the vessel being evacuated to be pulled below 3 psig using the exist ing piping. 3. Evacuating a Compressor for Maintenance Before taking a compressor down for maintenance, the lines to and from the compressor must be isolated and the VCM vapors removed (down to below 0 psig). This can be done by using the emission recovery system. When using the emission recovery system. VCM Unloading Operating Manual page 31 ABD00242768 II. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 3. Evacuating a Compressor for Maintenance (Cont.) Compressor No. 5 must be evacuated by a different procedure than the other compressors. a. Using the emission recovery system: NOTE: Not for Compressor No. 5. (L) Close the 3" valve coming off the sphere vapor line for the compressor to be evacuated. Tag the valve with a "Do Not Operate" tag. (2) Close and tag the 3" valves on the east side of the compres sor shed that are on the transfer lines coming from the compressor that is to be evacuated. The valves on the transfer line and the valve from Compressor No. 5 must be closed and tagged. (3) Close and tag the valve on the compressor liquid trap and the valve above the rotameter. (4) Open the 1" manual valve that will evacuate the blocked off lines to the emission recovery system. (5) Open the actuated valve that evacuates the line to the emission recovery system. On some of the valves this can b done by overriding the valve and blocking off the air. On the ones without overrides, block the air off on the valve to the liquid line (to keep it closed) and open the vapor valve by using the switch at the transfer stations (on the platform). ABD00242769 VCM Unloading Operating Manual Page 32 II. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedres (Coni.t) 3. Evacuating a Compressor for Maintenance (Cont.) (6) When the pressure reaches less than 0 psig on the compres sor, close the actuated and manual 1" valves on the line that goes to the emission recovery system. Be sure to open the air valve for the actuated valve on the liquid line if it was closed in step (5). (7) Close the air-r to the actuated valve on the vapor line and tag it. The compressor should now be ready for maintenance. (Make sure maintnenace blinds all the lines when working on a compressor). b. Using the emission recovery system for Compressor No. 5: NOTE: One of the other compressors must also be evacuated because the emission recovery system valves tie in only to the four transfer lines dwonstream of the Compressor No. 5 block valve. (1) Same as step (1) in (a) above. (2) Close one of the 3" valves on the vapor station transfer lines at the east side of the compressor shed. Open the valve on that line from the Compressor No. 5. Leave the Compressor No. 5 block valve open. Close the 3" valve that comes off of the sphere vapor line on the west side of the compressor shed that will isolate the compressor that discharges to the transfer line which was blocked off. (3) Same as step (3) in (a) above. " VCM Unloading Operating Manual i _i__.page 33 ABD00242770 ix. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 3. Evacuating a Compressor for Maintenance (Cont,) (4) Same as step (4) in (a) above. (5) Same as step (5) in (a) above. (6) When the pressure reaches less than 0 psig on Compressor No. 5, block off the Compressor No. 5 block valve on the east side of the compressor shed and tag it. (7) Close the actuated valve that was opened in step (5) and reopen any air that was blocked off. (8) Open the blocked in 3" valves on-the east and west side of the compressor shed that were closed in step (2). Compressor No. 5 should now be ready for maintenance.' 4. Lack of Liquid Plow in Sight Glass Occasionally, there will be little or no liquid flow in one or more of the liquid sight glasses after starting up the compres sor, even though all the valves are open. This may be caused by a lower pressure on one of the railcars, more pressure drop in one of the lines due to length of pipe, or other reasons. This problem only occurs occasionally and it usually happens in only one of the transfer lines. If there is not a closed or partially closed valve in the line, the problem usually corrects itself after 5-10 minutes. To speed up this process, use the following operating procedure. a. First, trace all the lines and check the valves going to and from the transfer station that is giving the problem. Make sure that all the valves are fully open and that the compressor discharge pressure is normal. VCM Unloading Operating Manual Page 34 II. OPERATING PROCEDURES (COnt.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 4. Lack of Liquid Plow in Sight Glass (Cont.) b. After making sure that all valves are open and pressures .... are normal, open the valves on the No. 5 compressor header to put all compressors on a common header (if these were not already open). c. Close the vapor transfer valve on the lines of one or more of the cars which are flowing normally. This will put more flow to the transfer station that is having trouble. d. After establishing normal flow in the sight glass that was giving problems (this usually takes only a minute or two), reopen the vapor transfer valves to the other transfer stations. Normal flow will usually be reestablished in the other transfer lines when the valves are reopened. e. Close any valves that you opened on the No. 5 compressor header. 5. Tank Car Excess Flow Valve Closing Occasionally, the excess flow valve on a tank car will close. This is caused when the flow in the line exceeds a set flow rate. This condition can be detected either when the liquid valves are opened and a pinging noise is heard at the dome of the car or when the compressors are started and there is no liquid flow in the sight glass and all valves are open. Usually there will be a pinging sound in the car dome when an excess flow valve shuts off. This situation can be overcome by hooking up the other liquid line at the transfer station. If it is already hooked up, use one or a ABD00242772 fc. VCM Unloading Operating Manual Page 35 XI. OPERATING PROCEDURE (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 5. Tank Car Excess Flow Valve Closing (Cont.) combination of the following procedures: ...a. Partially close the liquid valves on the dome of the car. This will slow down the flow and should reseat the valve, b. Turn off the compressor and let the car unload itself for a period, then restart the compressors. This can usually be done only in summer conditions. NOTE: If the excess flow valves shut in a car that has both liquid lines hooked up, this indicates that the valve is probably faulty. The car number should be noted so that it can be shopped after unloading. On ACFX and PPGX cars, the excess flow rates are set at a lower flow rate than on most UTLX, RTMX,.and NATX cars. For the ACFX and PPGX cars, the liquid lines should always be hooked up to each car. 6. Evacuating The VCM Vapor Line Knockout Pot and Recycle Pump For Maintenance Before taking the knockout pot and recyclye pump down for main tenance; the pot, pump, and related piping must be isolated and the VCM vapors removed (down to below 0 psig). This will be done by using the emission recovery system. a. Close the 4" inlet and outlet valves to the knockout pot. Tag these valves with "Do Not Operate" tags. b. Close and tag the recycle pumps's IV discharge and recir culation valves. ^BD00242773 VCM Unloading Operating Manual Page 36 II. OPERATING PROCEDURE (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) . 6. Evacuating the VCM Vapor Line Knockout Pot and Recycle Pump . For Maintenance (Cont.) . x,- Open the 2" manual valve that will evacuate the knockout pot and pump to the emission recovery system, d. When the pressure in the knockout pot and on the pump reaches less than 0 psig, close the 2" valve to the emission recovery system. The knockout pot and pump should now be ready for maintenance. VCM Unloading Operating Manual page 37 ABD00242774 XXI. EQUIPMENT INDEX A. T-601 (Sphere) - Conoco No, 93-001 Purpose VCM storage tank which holds fresh VCM taken from railcars for use in the reactor units. Description Spherical tank, mounted on 9 columns, 54' - 9" diameter, 57* overall height, with capacity of 640,594 gallons, carbon steel construction, built in 1975. Normal Operating Conditions Ambient Temperature and 10-60 psig. Design Conditions: 125 F and full vacuum to 100 psig. Relief Settings Rupture discs (2) = 100 psi @72 F. Safety valves (2) = 100 psi. B. Bullets: T-201 (West) and T-202 (East) - Conoco Nos. 89-201 & 89-202 Purpose Spare VCM storage tanks to hold fresh VCM from railcars for the reactor units or to store inerts from RVCM receivers if incinerator goes down. Description Horizontal-mounted, 80' straight wall length, 10* - 10V diameter, with approximate capacity of 61,450 gallons, carbon steel construction, built . in 1962. Normal Operating Conditions Presently kept at ambient temperature and approx imately 0-20 psig. Design Conditions: 250 psig maximum allowable working pressure. Relief Settings : Rupture discs (2 per vessel) 136 psi @72F. Safety valves (2 per vessel) = 150 psi. C. Big Corken Compressors (Compressors No. 1, No. 2, and No. 4) Purpose Unloading and evacuation of VCM tankcars. Description Corken model 690, 2-cylinder, 825 RPM vapor com pressor. Normal Operating Conditions Rated for 60 ICFM at 825 RPM, 295 psig maximum dis charge pressure. Relief Settings North - Cannot read tag, 250 psi when purchased. South - 225 psi. VCM Unloading Operating Manual Page 38 III. EQUIPMENT INDEX (Cont.) D. Little Corken Compressors (Compressors No. 3 and No. 5) Purpose : Unloading and evacuation of VCM tankcars. Description : Corken Model D490, 2-cylinder, 825 RPM vapor compressor. Normal Operating Conditions Rated for 35.5 ICFM at 825 RPM, 295 maximum discharge pressure. Relief Settings North - No tag, 250 psi when purchased. South - 250 psi. E. Sphere Transfer Pumps (North and South) Purpose To transfer VCM liquid from the sphere to the old or new unit fresh VCM receiver. Description Centrifugal type, Duriron A50, 3 x 1% - 10, 3500 RPM. Normal Operating Conditions : Rated for 150 GPM at 252" of differential head. F. Bullets Transfer Pumps (East and West) Purpose : To transfer VCM liquid. Presently not in use. Description : Centrifugal type, Duriron A50, 3 x 1*5 - 10, 3500 RPM. Normal Operating Conditions : Rated for 150 GPM at 252" of differential head. G. Emission Recovery System Knockout Pot (T-201) - Conoco No. 45-305. Purpose : To collect miscellaneous VCM emissions. Description : Vertical-mounted, four-foot straight wall height, eight-foot overall height, four-foot diameter with an approximate capacity of 470 gallons. Normal Operating Conditions : Ambient temperature and 3 psig. Design Conditions: 150 psi at 366F. Relief Settings : Rupture disc = 150 psi @ 72F. Safety valve = 150 psi. VCM Unloading Operating Manual Page 39 ABD00242776 III. EQUIPMENT INDEX (Cont.) H. VCM Knockout Pot (T-202) - Conoco No. 45-061 Purpose To remove liquid VCM from the vapor line and prevent liquid slugging of the compressors. Description : Vertically mounted on supports 6 feet above grade, 5-foot straight wall height, 2.5-foot diameter, . . with capacity of 150 gallons. Normal Operating Conditions 70 F and 40 psig. Design Conditions: 150 psig @ 200 F. Relief Valve Setting ' : 150 psi. I. VCM Recycle Pump (P-250) Purpose Removal of knockout pot contents to sphere. Description CMP model #3 x lh x 5, canned centrifugal pump,. 3 HP driver. Normal Operating Conditions : 10 GPM @ 58 feet of differential head. Relief Valve Setting : 170 psi. J. Compressor Low Pressure Switches Purpose : To shut off compressors at the end of vapor recovery from railcars. Description : Static-O-Ring diaphragm type. Set Point : 6 psig decreasing. K. Vapor Line Knockout Pot Level Switches - High and Low Purpose To start and stop VCM recycle pump as liquid VCM collects in the knockout pot. Description Robertshaw switches. VCM Unloading Operating Manual .J> Page 40 ABD00242777 IV. SAFETY EQUIPMENT AND SYSTEMS A. Continuous Flow Fresh Air System In order to provide personnel protection, a continuous flow fresh air system has been installed. This system consists of personnel fresh air masks and a constant flow breathing air supply. The supply lines are piped to various locations around the VCM tank farm. The indiviual hookup stations consist of quick connect/disconnect-type fittings. The individual line to the area is designed to allow a minimum flow of /* 6 SCFM to each mask at approximately 10-15 psig. An air pressure regu lator, shutoff valve, and an air filter are provided at the piping header to the area. Fresh Air masks are required to be worn during the following tasks: 1. Opening railcar dome lids, hooking up or disconnecting VCM tankcars. 2. Any time you enter the tank farm compressor shed, whether the compressors are running or not. 3. Whenever performing leak detection operations where the VCM con-r centration is expected to exceed 10 ppm. 4. Entering any vessel that normally contains VCM. 5. Blanking or line breaking of any line or vessel which has contained VCM. Clean fresh air masks are stored in the yard scalehouse. After using the mask, it should be properly disposed of by placing it in the used fresh air mask receptacle inside the yard scalehouse. Fresh air masks t are not to be left on the transfer station platform at the tank farm. 3 ! !I ^esBa ----------------------- \ ABD00242778 VCM Unloading Operating Manual Page 41 IV. SAFETY EQUIPMENT AND SYSTEMS (Cont.) B. VCM Canister Masks VCM Canister Masks may be used under the following conditions:. 1. Working in a contaminated area of less than 10 ppm VCM for up to 10 hours. NOTE: If the HNU monitor reads greater than 10 ppm VCM, a fresh air mask must be used. 2. Performing leak detection operations when Honeywell units are indicating between 1 and 10 ppm VCM. 3. Escape from an area of high concentration of VCM to obtain a Scott Air Pack. C. Scott Air Packs Scott Air Packs are self-contained breathing equipment and must be worn when entering concentrations of VCM which are above 1000 ppm or in unknown concentrations. Scott Air packs are located south of the sphere near the electrical breaker switches and north of the compressor shed. D. Firewater System The firewater system consists of a deluge system on the bullets and compressor shed, a 6" weir to the top of the sphere, and fire monitors. All firewater to the tank farm deluge systems and monitors is supplied by the six diesel operated fire pumps from the firepond and Number 5 waste water pond. Process water can be used in fire fighting by hook ing hoses to the fire hydrant south of the tankfarm in the MCC area. 1. Fire Monitors There are four fire monitors located around the diked area at the VCM tank farm. Three of these are kept pointed toward the bottom of the sphere with the manual valve to them.open. Water can ABD00242779 VCM Unloading Operating Manual page 42 XV. SAFETY EQUIPMENT AND SYSTEMS (Cont.) D. Fire Systems (Cont.) V 1. Fire Monitors (Cont.) be sent to these monitors by opening the tank farm monitor switch on the module charge panel in the vinly control room. Opening this, switch operates a pressure switch that automatically turns on the. fire pumps. A manual backup switch is located south of the sphere at the tank farm. The monitors should be used to lower VCM concen trations in the area -in the event of a VCM leak or to help put out fires. (A manual bottle back up system can also be used to open this fire monitor supply valve.) 2. 6" Weir To Top of Sphere Water can be sent to the top of the sphere by activating a.switch on the old module charge panel in the vinyl control room. A manual backup switch is located south of the sphere at the tank farm. Thermal sensors under the sphere can also activate the system and send water through the weir. Water through the weir is rated at 3000 gpm. The primary purpose of the weir is to supply water for cooling the sphere in the event of a fire in the area. (A manual bottle backup system can also be used to open this weir supply valve.) 3. Deluge System The deluge system supplies water through sprinklers to cover the bullets and the compressor shed. This system can be set off with a switch on the old module charge panel in the vinyl control room. The valve must be manually reset at the concrete basin north of the bullets. A manually activated trip is located at the basin. ABD00242780 VCM Unloading Operating Manual Page 43 IV. SAFETY EQUIPMENT AND SYSTEMS (Cont.) D. Firewater System (Cont.) 3. Deluge System (Cont.) Thermal sensors under the compressor shed or on the bullets can also set off the deluge system. The deluge system is designed to lower VCM concentrations in the bullets and compressor shed area, to cool the bullets in the event of fire in the area, and help put out fires. Because of the dikes around the sphere and bullets,.fire water should be used -judiciously in the area. The dikes are designed to contain any VCM spill from the vessesl. The VCM will float on water, and if the dikes are overfilled liquid VCM will be allowed to escape from the area, enlarging the hazard. The dikes can be drained with post-indicator valves on the west .side of. the dikes. If a dike is drained, make sure that the drain is closed after draining. The valves are to be checked daily. The person draining the dike should stay in the area and close the valve when draining is completed. The four actuated valves on the sphere inside the dike can be closed from the old module charge panel in the vinyl control room or from switches outside of the dike, south of the sphere. (These are the valves that are tested every Wednes day - See Appendix B for checklist). E. Fixed Point VCM Monitor A fixed point VCM monitor is used to detect VCM and record the VCM concentration at various locations at the VCM tank farm. The recorder and alarm annunciator are located in the vinyl control room. The vinyl panel operators will inform the yard operator of any high readings at the VCM tank farm. VCM Unloading Operating Manual page 44 V. EQUIPMENT ENTRY PROCEDURE ABD00242781 EPA standards for VCM emissions and OSHA regulations on personnel exposure to VCM require that certain operating procedures be followed when there is the possibility of VCM emission to the atmosphere or personnel exposure to VCM. For this reason and to ensure safe working conditions at all times, the "Engineering and Work Practice Control Program for the Reduction of Employee Exposure to Vinyl Chloride" manual should be consulted whenever equipment in the VCM tank farm is opened for any reason. This manual contains a list of detailed procedures as well as safety precautions for equipment opening. ABD00242782 VI. APPENDIX ABD00242783 A. VALVE SETUP CHECKLIST FOR UNLOADING VCM VALVES THAT MUST BE OPENED FOR UNLOADING: .1. Main liquid valve to sphere .(located under sphere). 2. Main vapor valve from sphere 3. Check sphere level Feet Inches. 4. Both valves on liquid and vapor lines hooked to car. 5. Valves inside car dome for vapor and liquid. * 6. Vapor and liquid going to stations between railroad track. 7. Vapor and liquid valves under sight glasses on each station being unloaded from. 8. Sphere liquid and vapor valve on main headers on west side of compressor shed. 9. 4-way valves on each compressor being used must be in vertical , position (handle). 10. Vapor line knockout pot inlet and outlet valves on west side of compressor shed. VALVES THAT MUST BE OPENED FOR RECOVERING VAPOR FROM RAILCAR: 11. Same as above except 4-way valves on compressor being used in horizontal position (handle). WHAT TO CHECK FOR UNLOADING: 1. Pressure gauages on compressors: a. Inlet Side - 20 to 50 pounds. If 0, compressor is full of liquid. b. Outlet Side - 60 to 110 pounds. If over 120, compressor is dead headed. 2. Sight glasses on liquid lines (flow of liquid). 3. Jamesbury valves on knockout pots closed to evacuation system. 4. No valve mentioned above partially closed. 5. Liquid VCM avove the low level switch in the vapor line knockout pot. CAR NUMBERS BEING UNLOADED: ABD00242784 B. CHECKLIST FOR TESTING AUTO-VALVE UNDER SPHERE MAIN LIQUID VALVE INTO SPHERE: Open (Test) Closed Open MAIN VAPOR VALVE INTO SPHERE: Open (Test) Closed LIQUID VALVE TO TRANSFER PUMPS: Open (Test) Closed RECIRCULATION LINE VALVE: Open (Test) Closed Open Open Open Test must be done while no unloading of railcars is taking place and there is no transferring to reactor buildings. Switches for test are located on north side of switchgear module at south end of VC tank farm. Tests are to be performed every Wednesday. OPERATOR: DATE: ^conocoj ABD00242785 PVC PLANT SAFETY & HEALTH MANUAL ABERDEEN, MS SUBJECT: FIRE PREVENTION AND EMERGENCY PLAN EFFECTIVE DATE: March 15, 1982 PREPARED BY: APPROVED BY: TITLE: MANAGER References: C FR 1910, Subpart L - Fire Protection, 1910.35, 1910.37, 1910.38 PURPOSE: Due to the nature of the chemical process industry and specifically, the Aberdeen Chemical Plant, the potential for a vapor release and/or fire can only be minimized by conscientious operation of the plant. Emergency conditions caused by human error or equipment failure can ultimately lead to serious personal injury,'loss of life, or severe damage to plant equipment. This plan is therefore being issued to: 1. Minimize the potential for fires and related emergencies through positive housekeeping and control of flammable materials and ignition sources. 2. Insure the safety and welfare of employees and the general public in the event of a plant emergency; 3. Minimize property damage and provide for the resumption of normal operations following a plant emergency; 4. Satisfy the legitimate concern of employees, their families, and the general public by providing prompt, accurate information concerning the extent and effects of plant emergencies; and, 5. Insure that all fire protection systems operate properly by routine testing and maintenance of critical systems. FIRE PREVENTION PLAN Fire related losses which can occur in the chemical industry are particularly severe. Due to the nature of the materials which are routinely handled in the Aberdeen Plant (primarily VCM, natural gas, propane, and other hydrocarbon fuels), operating personnel must exercise preventive control of hazards which can lead to fires. The Fire Prevention Plan is therefore being incorporated into the body of the Emergency Plan and its specific provisions will be reviewed on a routine basis by operating departments. Section 1,230 ABD00242786 FIRE PREVENTION AND EMERGENCY PLAN PAGE 2 FIRE PREVENTION PLAN - (Continued) Many of the materials used to make PVC and its compounds are flammable or combustible. Table I, below, is a list of commonly used materials which are flammable or combustible and can be fire hazards if not properly controlled. The majority of these materials are supplied as finely divided dusts and in some cases are capable of causing an explosion if dust accumulations are allowed to form an ignitable cloud. TABLE I VINYL DEPARTMENT Flammable Combustible PVC Initiators (Oxidizer) Gasoline Natural Gas/Propane Vinyl Chloride Monomer Alpha Methyl Styrene (AMS) Odorless Mineral Spirits (OMS) Bubble Breaker Cardboard Boxes Diesel Fuel 2-Ethyl Hexaldehyde Glycerine Methocel Paper Bags PC-555 Shell Sol 71 Code 83195 Hydroquinone COMPOUND 'DEPARTMENT Flammable Gasoline Combustible Antimony Trioxide 4310 R-l Violet Expoxidized Soybean Oil Bisphenol A Cardboard Boxes Color Concentrates (Vinyl Base) Cyasorb UV-531 Lead Stabilizers Dibasic Lead Stearate Ferro ThermOCheck 1827 Hal-Lub-D Hostalube XL 165 Hystrene 5016 "Mark" Compounds Mineral Oil Molydenum Trioxide Oncor 75 RA Paper Bags Plastiflow POP "Plastolein" Products PX-316 R-4067 (Interstab) Santicizer 419 Synpron 1438 "Vinyzene" Products Wax Lubricants (polyethylene, Petroleum) Section 1.230 Page 2 ABD00242787 FIRE PREVENTION AND EMERGENCY PLAN PAGE 3 DRY BLEND DEPARTMENT Flammable Gasoline Combustible "Acryloid" Products Acrawax "Advastab" Products Advawax Calcium Stearate Cardboard Boxes Diesel Fuel "Mark" Products Paper Bags Thermolite 101 Wax Lubricants (polyethylene, petroleum) PLASTICIZER DEPARTMENT Flammable Gasoline Combustible Alcohols Phthalic Anhydride "Darco" Carbon Black Cardboard Boxes Diesel Fuel Bisphenol A Paper Bags Sulfonic Acid Catylist (liquid) (Scott Air Pak and turnout gear required for fire fighting) MAINTENANCE DEPARTMENT Flammable Acetylene Amercor Mark III Gasoline Hydrogen Gas Natural Gas Propane Paints and Thinners Sulfuric Acid (generates hydrogen gas) Combustible Agitene (Regular, Super) Amerzene 35 Ammonium Nitrate (Highly Dangereous if mixed with Oils) Biocide 285 Biosperse 201 Cardboard Boxes Conoco Lube Oils and Greases Drewplex 505 Drewsperse 738 Mitee Thread Cutting Oil UCON Lubricants and Heat Transfer fluids LABORATORY DEPARTMENT Numerous flammable and combustible liquids and solids are stored and used in small quantities in this department. Section 1.230 Page 3 ABD00242788 FIRE PREVENTION AND EMERGENCY PLAN PAGE 4 Many of the above noted chemicals classified as combustible are used routinely and are not commonly thought to be fire hazards due to the very high temperatures required to ignite, them. Special precautions are outlined in the Safety. Control Permit System Procedure which will govern all hot work operations in areas where flammable or combustible materials are used or stored. Hot work in the vinyl and propane processing area should be allowed only when there is no other reasonable method. Fire protection and control systems used in the plant range from simple hand held fire extinguishers to sophisticated water spray deluge systems. This equipment is routinely checked by Safety and/or Instrument Personnel to insure that it operates properly when needed. The Safety Director is responsible to see that all fire protection systems are maintained in an operational condition.' Supervisory personnel plant wide are responsible for controlling fuel source hazards through conscientious operation and the Safety Control Permit System. Smoking will be permitted only^ in areas of the plant specifically specified for that purpose. Fire protection rules in the Safety Rule Book will be strictly adhered to. Table II, below, is a listing of fire protection equipment which is available for use in the event of a fire related emergency. TABLE II FIRE FIGHTING EQUIPMENT Equipment Area(s) of Coverage Diesel Driven Fire Pumps for Water Supply (4-2000 GPM, 100 psig Units - North pump house) (2-2000 GPM, 130 psig Units - South pump house) Areas processing.vinyl chloride monomer (propane area upon comletion of phase III fire protec tion improvements). Process Water System Propane area fire protection equipment, warehouse area sprinkler systems. Deluge Spray Systems Vinyl reactors and tank farm. Fire Monitors (Fixed) Vinyl reactor, VCM and propane tank farm, VCM incinerators. Fire Monitors (Portable) Emergency equipment station, initiator storage freezers. Dry Chemical Wheeled Fire Extinguisher s New reactor module, olcl reactor module, south compound cooling tower. Dry Chemical Hand Portable Fire . Extinguishers Hose Houses and Fire Hydrants Various locations plant wide. Various locations plant wide. Section 1.230 Page 4 FIRE PREVENTION AND EMERGENCY PLA#BD00242789 PAGE 5 TABLE II (Continued) Equipment_____________________________________ Area(s) of Coverage_______ 1*5 inch Fire Hose and Nozzles Warehouse areas and vinylreactor and propane tank -, farm areas. Fire Turnout Clothing (Hats, Coats, Boots and Gloves) Available for use plant wide, stored in the Emergency Equip ment Station. Extra Fire Hose (3 inch hose with 2^ inch couplings) Hose reel cart in Emergency Equipment Station. Scott Air Paks Various locations plant wide. Additional Firefighting Nozzles and Related Equipment ,. Available for use plant wide, stored in the Emergency Equipment Station. CO2 (Carbon Dioxide) Fire Extinguishers Laboratory and Motor Control Centers. Halon 1211 Fire Extinguishers Behind vinyl control panel and in telephone switching room,. HOUSEKEEPING - Along with proper control of flammable and combustible materials, maintenance of high housekeeping standards is critically important. The proper disposal of trash from the various plant operations will minimize the accumulation of combustible materials and thereby reduce the potential for fire. The following is a list of basic housekeeping requirements for fire prevention purposes. 1. Ordinary hazard materials such as floor sweepings, paper bags, used filters, rags, and other miscellaneous discarded items shall be placed in dumpsters which are routinely dumped Into the central trash compactor. 2. Initiator bottle disposal shall be done in accordance with current Vinyl Department procedures. Disposal of initiators which cannot be used in our operations shall be done under supervision of the Safety Department. . 3. Inventories of empty drums in the various operating areas shall be kept to a minimum. All empty steel drums shall be taken to the drum storage area east of the API separator. Empty fiber'drums should be placed in the large open top trash containers located south of the plasticizer building. 4. Clean-up and disposal of dust type materials which have been contaminated with a substance hazardous to health, such as lead, shall be done with vacuum cleaning methods, 5. Housekeeping requirements for operations which involve hot work are specified in the Safety Control Permit System Procedure. 6. Motor control center areas (breaker rooms) shall be maintained free and clear of discarded materials and shall not be used as storage areas. Whenever breaker panels are located in storage areas, a clear access lane of at least 36 inches from the front of the breaker panel shall be maintained. Section 1.230 Page 5 ABD00242790 FIRE PREVENTION AND EMERGENCY PLAN PAGE 6 HOUSEKEEPING - (Continued) 7. Containers of laboratory solvents and reagents, once empty, shall be disposed of as ordinary hazards (see paragraph 1). Waste chemicals . shall be disposed of in accordance with approved waste disposal pro-., cedures. FIRE PROTECTION SYSTEM MAINTENANCE - The fire protection systems and equipment used in the plant undergo routine testing and maintenance. The Safety Director is responsible to see that all systems are operational and. that routine testing is accomplished. Also, he is responsible to see that repair work on systems and equipment is accomplished on a timely basis /. whenever problems are discovered. Table III below specifies testing require ments and frequencies for the various systems and equipment. TABLE III FIRE. PROTECTION SYSTEM ....... AND ... EQUIPMENT MAINTENANCE System/Equipment Frequency Checkout Requirements Fire Pumps Weekly 1) All engines start on pressure drop and sequence. 2) Battery and charger condition. 3) Engine operating temperature. 4) Engine oil pressure. 5) Engine hours. : 6) Fuel levels. 7) Flowing and static pressure. 8) Engine RPM Annual 1) Flow studies, 2) Verify engine RPM with tachometer 3) Cooling system flush and charge with fresh coolant. 4) Verify thermostat operation. Deluge Systems (Reactors & Tank Farm) Weekly 1) Flow gas over gas detector field sensors on gas detection system - check for system release. 2) Proper operation of deluge valvestrip and reset, 3) Systems drain freely. 4) No breaks in deluge piping systems Quarterly 1) Check flowing pressure on each system. Section 1.230 Page 6 FIRE PREVENTION AND EMERGENCY PLA^BD242791 PAGE 7 FIRE PROTECTION SYSTEM MAINTENANCE - (Continued) Svs t em/Equipmen t VCM Storage Sphere Fire Monitor Nozzles Stationary Fire Monitor Nozzles Sprinkler Systems Post Indicator Block Valves and Other Fire System Valves In Each Unit Fire Hose Fire Extinguishers TABLE III (Continued) Frequency Checkout Requirements Weekly 1) Remote and local control operation of actuated valve (pit). 2) Nozzle orientation directed at bottom half of sphere. SemiAnnual 1) Free operation of valve. 2) Flush until water is clear. 3) Nozzle free of debris. Annual *r 1) Flow test at inspector check point. 2) All systems protected by anti freeze solution if wet. Weekly 1) Check to insure that firewater supply valves to unit deluge valves are open and locked. 2) Verify all thermostatic release air line valves are open and locked. Monthly 1) Check to insure that' all'underground supply line block valves are open and locked. Annual 1) Hydrostatic pressure test of at least 200 psig maintained for at least 15 seconds. 2) Hose shall not leak or jacket threads break. 3) Dried and reinstalled in hose house, or rack, preconnected to hydrant or supply valve. Monthly 1) Fluff dry chemical powder, . 2) Charged to specified pressure or CO^cartridge seal in-tact. Release mechanism sealed. 3) Cylinder hanger, handle, and hose undamaged. 4) Wheeled units - hose properly coiled, valve in OFF position. 5) Stamp each extinguisher tag to indicate it has been inspected. Section 1.230 Page .7 ABD00242792 FIRE PREVENTION AND EMERGENCY PLAN PAGE 8 FIRE PROTECTION SYSTEM MAINTENANCE - (Continued) TABLE III System/Equipment Frequency Checkout Requirements Fire Extinguishers (Hydrostatic) Five or Twelve Years 1) Done under contract with licensed cylinder hydrostatic test contractor. Emergency Alarm Monthly 1) Test alarm modes (vapor, fire, evacuation) one per month on rotating cycle. 2) Test public address systremalarm and all clear. Smoke Detection System SemiAnnual 1) Check voltages, detectors and alarm signal devices for proper operation. 2) Check, supervisory circuitry. CO2 Fire Extinguishing System - Lab Chemical Storage Room Semi~ Annual 1) Weigh CO^ supply bottles, refill as needed. 2) Check actuating mechanism for proper operation. 3) Check pre-alarm for operation and audibility. 4) Assure that all piping connections are secure and that there are no system leaks. EMERGENCY PLAN Definition of Plant Emergencies A plant emergency is any unexpected event or condition which requires immediate action to prevent injury to personnel and/or damage to equipment. Plant emergencies include, but are not limited to: fires, explosions, release of toxic, flammable, or corrosive materials, or an injury which requires removal of an employee from an elevated location, A "Vinyl Chloride Emergency" is any massive release of vinyl chloride. This does not include, minor leaks of temporary concentrations above permissible exposure limits. ' i Immediate Actions to be Taken in Event of a Plant Emergency Immediate actions are the direct responsible of the Emergency Officer. his absence, they are the responsibility of the Emergency Crew Chief (Shift Supervisor). In Section 1.230 Page 8 ABD00242793 FIRE PREVENTION AND EMERGENCY PLAN PAGE 9 EMERGENCY PLAN - (Continued) Immediate Actions to be Taken in Event of a Plant Emergency - (Continued) The extent and severity of a plant emergency shall dictate the extent to which the emergency plan is utilized. The initial determination of required action shall be made by the Shift Supervisor in charge of the affected area(s). The action taken may range from handling the emergency with personnel present at the time to full alert of the emergency organization. In general, the .. following actions, as applicable, are required during an emergency: 1. Activate the Emergency Alarm System Anyone who detects an emergency situation shall communicate it to the Vinyl Control Room by the radio, the Gaitronics System, or by dialing 2200 on the plant telephone system. In. each case, the caller shall clearly communicate the location and nature of the problem to control room personnel (this information must be recorded on the forms provided). The Operator who takes the message shall then activate the appropriate alarm by depressing that button on the emergency alarm system contol panel. Once the alarm sytem has been activated and the alarm is no longer operating, the operator shall dial 641 on the plant telephone system and give the nature and location of the emergency in a clear, calm, and distinct manner. This message must be given a minimum of three (3) times in order that plant personnel understand the nature and location of the problem. Plant Emergency Alarm Codes The plant emergency alarm siren is a dual tone type which produces a high and low pitch simultaneously during normal operation. Signal coding is achieved by alternately turning the siren motor on and off, and by opening and closing the air supply tubes feeding the rotating (sound producing) elements of the siren. On the following page is a graphical illustration of the alarm codes used in the Aberdeen Plant. Whenever a plant emergency occurs, the nature of the problem will be communicated to the plant via the siren and the plant P.A. system as noted . above. If the conditions require a general plant evacuation, the evacuation signal should be given only after the fire or vapor alarm. This allows evacuation signal to act as a tornado warning when used by itself as noted in the storm warning section below. 2. Use the Proper Emergency Equipment All employees directly engaged in correcting emergencies involving VCM liquid/or vapor concentrations in excess of permissible exposure limits (.1 ppm averaged over an 8-hour period with excursions to 5 ppm averaged over a 15 minute period) shall be equipped with personnel protective equipment which is appropriate for the hazards involved. In the case of VCM emergencies, the location of the spill must be evaluated prior to action on the part of any employee. If the discharge is occurring from a reactor relief line, Scott Air Paks may be the only personnel protective equipment required. In the case of major discharges which occur in and around electrically driven process equipment, the Supervisor in charge may require his personnel to also wear full fire turnout gear to maintain Section 1.230 Page 9 ABD00242794 FIRE PREVENTION AND EMERGENCY PLAN PAGE 9 PLANT EMERGENCY ALARM CODES Vapor (Steady Signal) FPQU/JCY {P/TCP) CQWFP PPQUA/CY fP/TCH) Fire (Wailing Signal) Evacuation (Undulating Pulsed/ Pool Tone Signal) All Clear Dial: 2209 OR 2210 ABD00242795 r FIRE PREVENTION AND EMERGENCY PLAN PAGE 10 f1TS'TJ*. EMERGENCY PLAN - (Continued) 2. Use the Proper Emergency Equipment - (Continued) {' i safety in the particular emergency operation. Whenever emergency situations occur where liquid (VCM or propane) is involved, personnel must wear special heat and liquid resistant gloves to protect from freeze burns and potential flash fires. 3. Evacuate Non-Essential Personnel from Danger Areas Always evacuate non-essential and all personnel not properly equipped with personnel protective equipment which is appropriate for the hazards present. Emergency crews are to report to the emergency location as directed in the Emergency Crew Section below. . Such personnel shall not be allowed to return until the emergency situation has been corrected. In all cases, evacuated personnel shall immediately proceed to primary evacuation areas as noted below. If the wind directs hazardous vapors into the primary evacuation areas, evacuated personnel shall proceed to the secondary evacuation area at the guardhouse and assemble in departmental groupings as noted on the fence located east of the parking lot and south of the guardhouse. If that area is noted as being contaminated by VCM vapor, evacuated personnel will be moved to a safe location along the property line,,north of the plant. ALL EVACUATIONS MUST BE PROMPT AND ORDERLY!. . Section 1.230 Page 10 ABD00242796 FIRE PREVENTION AND EMERGENCY PLAN PAGE 12 EMERGENCY PLAN - (Continued) 6. Activate Fire Protection Systems Activate and utilize Emergency Crews, support personnel present (under the direction of the Mechanical Superintendant as noted in the EMERGENCY ORGANIZATION SPECIFIC DUTIES section below) and the Emergency Organization as necessary to prevent or extinguish fires, explosions, or chemical exposures. Activate the deluge system and/or fire monitors as follows: Deluge System - These systems should be activated whenever emergencies require deluge system operation. These emergencies include but are not limited to the following: Serious leaks from rotating equipment seals. - Abnormal discharges of flammable material from process piping, valves, and relief systems. - Serious leaks in the VCM compressor shed at the tank farm. (CAUTION: Water can damage the Corken compressors if they are hot. The system should be used only during,fire conditions or when serious VCM leaks may cause a fire. In all cases, the appropriate piping should also be blocked in to prevent the release of large amounts of VCM). Fires resulting from any of the above. Fire Monitors - Permanently installed fire monitors in the various areas provide supplemental fire water to locations which may need additional water for equipment protection due to direct flame inpingement, high concentrations of VCM vapor, or during periods when the deluge system is out of service. During VCM vapor releases which involve the reactor relief systems, the Supervisor may decide to utilize only the fire monitors since the point of discharge is above all other operating equipment. Due to high volume demand of the deluge systems, fire streams from monitor nozzles may not reach the top of the relief lines with both systems in operation. If supplemental fire water is needed of in cases where there is no permanently installed fire protection system (i.e. the initiator freezers), the Supervisor should utilize the portable fire monitor and hose reel stored in the Emergency Equipment Station.* Lead Operators should make sure the fire pumps are operating when major leaks occur in the reactor areas and only the fire monitors are in use. If the pumps are not operating and there is flow through the monitors from the process water system,, the . pumps can be started by briefly opening and closing the deluge water valve . to the sphere from the old module control panel. (NOTE: For additional information regarding the operation of fire protection equipment in the VCM tank farm area, consult the VCM Tank Farm Operating Manual.) VJ Whenever the fire alarm is activated, all hose crews shall report to a location upwind of the fire, and assemble by emergency crew grouping. The Chief and Assistant Chief shall survey the problem and'direct their personnel accordingly. In all cases where significant size fires are noted, fire fighting personnel must be properly outfitted with fire turnout gear. * Phase IV of the Fire Protection Improvement Project will provide a hose house at the initiator storage freezer. Section 1.230 Page 12 FIRE PREVENTION AND EMERGENCY PLAI^BD00242797 PAGE 11 PRIMARY EVACUATION AREAS Vinyl Area - At pad north of the control room. Lab & Compound/Plasticizer - Warehouse at northwest corner of the staging . area directly south of the plant auditorium. Maintenance, Receiving Warehouse/Stores. Yard - Main shop Transportation - Warehouse at northwest corner of the staging area but east of the lab and compound/plasticizer group. . Off-Shift Yard and Mechanics - At pad north of vinyl control room. Office Personnel - Lobby in each office area. Contractors - North of main gate. 4. Account for all Personnel When personnel have assembled in the primary evacuation areas, head counts must be made as noted in EVACUATION OF WORK AREAS below. Personnel not accounted for at this time must be regarded as trapped and/or injured and rescue efforts initiated. It is extremely important for all personnel to understand the location of their primary evacuation areas and to get to them as quickly as possible; otherwise, other personnel may have to jeopardize their personal safety during search and rescue operations. NOTE: Where supervisors have been pre-assigned duties under this plan, other arrangements must be made by the various departments to insure that personnel are accounted for on a timely basis (see evacuation of work areas for more information). 5. Rescue Trapped Personnel Search, and rescue operations during VCM and propane vapor releases and fires must be attempted only with fire turnout gear due to the likelihood of vapor ignition causing a flash fire or explosion. In the event that rescue operations are required during serious plant emergencies, the Emergency Officer (Emergency Crew Chief on off shifts) will utilize personnel who are not assigned specific emergency duties to conduct search and rescue operations. In all cases, the buddy system isrequired to perform these duties and the Emergency Officer must take that into account as he assigns the duties. Personnel protective equipment . requirements must be defined by the Emergency Officer. This can vary from nothing to the .use of fire turnout equipment and Scott Air Paks depending upon the circumstances. Rescue operations may become necessary due to serious personal injury in elevated plant locations. In this event, the rescue equipment kept in first aid and the Emergency Equipment Station must be assembled and utilized by plant personnel under the joint direction of the Emergency Officer and either the Plant Nurse or ambulance attendant. Section 1,230 Page 11 ABD00242798 FIRE PREVENTION AND EMERGENCY PLAN PAGE 13 EMERGENCY PLAN - (Continued) 6. Activate Fire Protection Systems - (Continued) Water Wall Nozzles - Special nozzles which are used to protect other exposed equipment during emergencies are available in the emergencyequipment station. The water wall nozzle is designed to be coupled . in between or at the end of our large (3 inch) firehose. The pattern of water supplied by these nozzles creates a vertical curtain of water that could be used to protect cooling towers, other vessels, equipment or buildings during fires. 7. STOP ALL HOT WORK! - Motor vehicles, portable transfer systems, the incinerator, welding machines and and other source of ignition must be positively shutdown immediately whenever the plant emergency alarm is activated! Shut down and secure operations as required to.prevent further injury to personnel or damage to equipment. 8. Stop flow of: A. Flammable materials feeding fires or potential fires, including dryer and incinerator gas burners. B. Boilerhouse operation is to be shutdown only in cases where unfavorable wind conditions and flammable material release is great enough to present a hazard. Boilerhouse shutdown can occur only on direct orders from the Emergency Crew Chief:,, the Emergency Officer, or the Safety Director. 9. Utilize outside assistance and notify the community as required. A. Aberdeen Fire Department ........................................................... 369-9551 B. Ambulance..................................................................................................369-2455 C. Hospital Emergency Room ........................................... '............... 369-2455 D. Dr, R. E. Coghlan (Office)........................ 369-2411 (Home)...............................................................369-4418 . E. Dr, J. N. Turnage (Office) ...................................................... 369-2413 . (Home)............................................................. 369-6311 F. Aberdeen Police Department ...................................................... 369-6454 Have local police warn adjacent plant and residential areas if they are threatened by fire, flammable material releases or toxic gases (chlorine or hydrogen chloride (HC1) as a result of a VCM fire). Plant Manager approval is required prior to contacting the police department unless the delay increases the danger to the community (see PUBLIC ALERT below). Section 1.230 Page 13 ABD00242799 FIRE PREVENTION AND EMERGENCY PLAN PAGE 14 EMERGENCY PLAN - (Continued) 10. Locate the boundaries of contaminated areas during vapor releases. This will normally be done by the Safety Supervisor during weekdays. The vinyl shift supervisor will perform this duty during off-shift hours only after he has successfully contained the emergency condition and completed the work assignments necessary to clear the emergency. RESPIRATORY PROTECTION REQUIREMENTS Plant emergencies involving VCM and chlorine shall require the use of Scott Air Paks. Emergencies involving propane and other materials require the use of Scott Air Paks only if concentrations of vapor might decrease the oxygen content of the leak area to levels which will not support life. REPORTING All emergencies will be reported by the Plant Manager to the General Manager of Manufacturing within 24 hours. For this reason, the Plant Manager must be informed in a.timely fashion of any emergency incident. The guidelines for reporting emergency conditions are shown below. I- I. Fires 1. Any fire which causes serious damage should be reported to the- Plant Manager immediately. 2. All other fire incidents should be reported to the Plant Manager by the next workday after the fire. All fires will be thoroughly investigated by a team appointed by the Plant Manager. A FIRE REPORT must be completed as rapidly as possible for use by the investigating team. Vapor Releases and Other Emergencies 1. The Operations Superintendent will issue a written report on each VCM emergency as soon as possible, not to exceed 24 hours. 2. The Plant Safety Director will report VCM emergencies and the facts obtainable to the OSHA Area JDirector as required by OSHA Regulations. 3. The Chief Process Engineer will report VCM emergencies and the facts obtainable to the Mississippi Bureau of Pollution Control and to the Regional Administrator of the Environmental Protection Agency as required by NESHAP and State regulations. 4. The Chief Process Engineer must be notified regarding any spill of a potentially hazardous material as soon as the spill is discovered; The Chief Process Engineer will promptly report the spill to the Superfund National Response Center if required by regulation. A PLANT EMERGENCY ALARM DATA SHEET must be completed by the operator whenever the alarm is activated (tests included). When completed, it must be sent to the Safety Director. Section 1.250 Page 14 ABD00242800 FIRE PREVENTION AND EMERGENCY PLAN PAGE 15 EMERGENCY ORGANIZATION Please refer to the attached EMERGENCY ORGANIZATION chart for the following discussion. When activated, this organization shall be directed by the ... Management. Group, which bears overall responsibility for meeting the objectives of the plan. Activation - Whenever an emergency occurs in the plant, The Shift Supervisor responsible for the affected area(s) will be in charge of all immediate, actions, including activation of the Emergency Organization if and as required. During normal office hours, the organization shall be activated by the Shift.Supervisor by announcing "ACTIVATE EMERGENCY ORGANIZATION" three (3) times over the P.A. system. During off hours and weekends, the Shift Supervisor shall instruct the Plant Guard to "call-out" the Emergency Organization. The Guard shall then call all personnel listed on the Emergency Organization Call List in rank order. If an individual cannot be reached, the Guard should then call the next person listed on the list. Once contacted, these personnel are to immediately come to the plant and assume their emergency duties. Specific Duties - The following is a discussion of specific duties assigned to each position in the Plant Emergency Organization. 1. Management Group The Management Group will consist of the Plant Manager, the Plant Superin tendent and the Employee Relations Director, The duties of the Mangement Group are: A. Provide leadership for the disaster group and coordinate all activities connected with control of the situation. B. Promptly release factual information to the news media, preventing erroneous reports and creating the best possible public image for the company. C. Notify Corporate Management and keep them up to date on the situation. D. Notify next of kin in cases of serious or fatal injuries. E. Maintain close communication with, the Emergency Officer. 2. Emergency Officer The Operations Superintendent of the area affected will serve as the Emergency Officer. He will report directly to the Management Group and will be in overall charge of emergency control activities. He will be assisted in this duty by the Safety Director and the Chief Process Engineer, The alternate to the Operations Superintendent is the Operations Supervisor of the area involved. The duties of the Emergency Officer are: A. Work closely with the Emergency Brigade Crew Chief in determining the most effective manner of establishing control of the situation. Section 1.230 Page 15 ABD00242801 FIRE PREVENTION AND EMERGENCY PLAN % PAGE 16 EMERGENCY ORGANIZATION - (Continued) 2. Emergency Officer - (Continued) B. Keep the Management Group informed of the situation and the action being taken to bring it under control. M . C. Rely on the advise and help of the Assistant Emergency Officer and k the Safety Director. t.. D. Issue instructions for the "Call-Out" of off-duty employees and 1', advise the Security Officer of who is authorized to enter the plant. 3. Assistant Emergency Of ficer The Chief Process Engineer will serve as the Assistant Emergency Officer. He will assist the Emergency Officer in the evaluation of the situation and the planning of action necessary to establish control of the emergency. He will also provide any technical information regarding the equipment or process that might be necessary. He will keep the Emergency Of ficer informed of his whereabouts at all times. The alternate to the Chief Process. Engineer is the Senior Process Engineer. 4. Security Officer The Security Officer position will be filled by the Safety Supervisor arid he will report directly to the Management Group. His specific duties are: A. Provide security protection for all plant property and material. This will include procurement and assignment of Guards, if needed. B. Dispatch personnel to the road blocks so that authorized personnel may be identified and allowed into the area. The unauthorized personnel must be turned back in a firm, tactful manner. C. Provide emergency supplies that might be needed during the emergency. D. Monitor VCM concentrations in the area of the secondary evacuation area southwest of the guardhouse. 5. Safety Director The Safety Director will assist the Emergency Officer in any way necessary in bringing the situation under control. His primary responsibility is in helping with fire fighting and rescue efforts. He will work closely with the Emergency Crew Chief. Following an emergency, the Safety Director will assist Department Heads in restoring safe condition throughout the plant. He will also see that emergency equipment is serviced and placed in the proper locations. He will act as a team leader to make a detailed study of the causes of the emergency, action taken, and any recommendations made to prevent similar emergencies. Section 1.230 Page 16 ABD00242802 FIRE PREVENTION AND EMERGENCY PLAN PAGE 17 EMERGENCY ORGANIZATION - (Continued) 5. Safety Director - (Continued) The Safety Director will also be responsible for the following areas of emergency readiness: A. Review the Fire Prevention and Emergency Plan on an annual basis and issue revisions in accordance with the work calendar..- B. Organize training programs as necessary to insure prompt and adequate response to emergencies in the following areas. Basic Fire Training - 1. Make sure that all operating, maintenance, support groups and professional personnel are exposed to basic fire fighting .. techniques pertaining to the use of portable fire extinguishers, emergency alarm systems and evacuation procedures. This will normally occur on an annual basis. New employees will receive basic fire training within 120 days of employment. Advanced Fire Training - 2. Vinyl Department employees and members of the emergency, crews, will tie trained more extensively in automatic fire control systems, operation of the plant fire water system, fire fighting methods and basic fire theory. First Aid - 3. Organize annual refresher first aid training of off-shift first aid personnel. C. Insure that fire fighting and emergency equipment is maintained in operable condition at all times, 6. Emergency Chief The Vinyl Shift Supervisor will fill the position of the Emergency Crew Chief during emergencies in the Vinyl Reactor, Vinyl Dryer, Boilerhouse, Waste Treatment and VCM Tank Farm areas. The Compound Shift Supervisor will act as the Emergency Crew Chief in the Compound, Plasticizer, Laboratory, Office and Warehouse areas. The appropriate Chief will direct the Fire Crew and others involved in fire control or other emergency action. He will work closely with the Safety Director in the effective., use of manpower and equipment necessary to bring the situation under control. Section 1.230 Page 17 ABD00242803 FIRE PREVENTION AND EMERGENCY PLAN PAGE 18 EMERGENCY ORGANIZATION - (Continued) 6. Emergency Chief - (Continued) The Emergency Chief will usually be the first individual in authority to recognize the existance of an emergency situation. He must make . the immediate decisions regarding the emergency action and continue in this capacity until the Emergency Organization can assemble, if it is required. The Vinyl Shift Supervisor, acting as the Emergency Chief, will initiate the necessary action to put this plan into effect. The specific duties of the Emergency Chief in time of emergency are listed under "IMMEDIATE ACTIONS..." section above. Once the Emergency Officer arrives, the Emergency Chief will report to him. 7. Assistant Emergency Chief ^' The Compound Shift Supervisor will serve as the Assistant Emergency Chief during emergencies in all areas of the plant, except Compound, Plasticizer, Laboratory and Warehouse. In those areas, the Vinyl Shift Supervisor will act as Assistant Emergency Chief. The Assistant Chief's duties will be as follows: A. Make sure that all of the Fire Brigade members in his area leave for the scene of the emergency. B. Report to the Emergency Chief for instructions. 8. .. Mechanical Chief The Mechanical Superintendent will act as the Mechanical Chief during the time of the emergency. The alternate is the Mechanical Superintendent, In this capacity, the Mechanical Chief will report to the Emergency Officer. He will carry out the following duties: A. Organize and direct damage control work as directed. B. He will be in charge of all personnel reporting to the Shop Area. C. Assist the Emergency Officer in any way necessary to bring the situation under control. D. Establish relations with outside utility companies and work closely with them, maintaining or restoring service as soon as possible. E. Notify the Security Officer of the names of those people in the plant under his direction and of any who have been called out. F. Keep the Emergency Officer informed of his whereabouts at all times. G. Organize and direct clean-up and repair crews for the purpose of getting the plant back into operation.as soon as possible. Section 1:230 Page 18 ABD00242804 FIRE PREVENTION AND EMERGENCY PLAN PAGE 19 EMERGENCY ORGANIZATION - (Continued) 9. First Aid Chief and Assistants The Nurse will act as the First Aid Chief and will report to the . Emergency Officer. The Laboratory Lead Technician will act as an - Assistant. The alternate for the Nurse will be the Laboratory Shift. Supervisor. A. The First Aid Chief and Assistants will go immediately to the emergency scene whenever the Emergency Organization is activated or there is a call for First Aid help. B. Give First Aid to the injured. C. Advise the Communications Chief if ambulances are needed. /' D. Keep the Management Group and the Security Officer informed of injuries, including the names and estimates of severity. E. Transport injured personnel to ambulance. 10. Messengers The Messengers will report to the Emergency Organization member to whom they are assigned. 11. Fire Pump Supervisor During the first shift on weekdays, the Safety Inspector will act as the Fire Pump Supervisor. When alerted by emergency signals, he will, report to the Fire Pump House. He will keep all four (4) pumps running until the "ALL CLEAR" is sounded. He will be assisted by the Toom Room Man. In the Tool Room Man's absence, the Day Shift Mechanic will assist the Safety Inspector. At all other times, the position of Fire Pump Supervisor will be filled by the on-duty Shift Mechanic. Whenever there is no coverage by any of the above, the Plant Guard shall insure that all fire pumps are operating. The Vinyl Shift Supervisor shall be responsible for the shutdown of the fire pumps when the emergency condition has been corrected. 12. Emergency Crews There are two emergency crews. The objectives of these crews are to, insure that, through quick action, we will be able to protect employees and minimize any damage due to fire. Both crews are to report to the announced location of the emergency immedia.tely when summoned by alarms, the Shift Supervisor, or when the Emergency Organization is activated. The crews will consist of the following: Section 1.230 Page 19 FIRE PREVENTION AND EMERGENCY PLANBD00242805 PAGE 20 EMERGENCY ORGANIZATION - (Continued) 12. Emergency Crews - (Continued) //I Emergency Crew . Emergency Crew Chief #2 Emergency Crew Vinyl Shift Supervisor Chief Operator Dryer "A" Operators (2) Dryer Utility Assistant Emergency Crew Chief * Compound Shift Supervisor Automatic Bag Operator Line I Bagging Utility Line III Mill Utility Dry Blend Utility - if available Line I Compounder Emergency Crew Duties - The prompt and proper response of Emergency Crew members is essential to the protection of lives and property. The following are the duties to be performed in the event of a serious plant emergency: A. Obtain fire fighting protective clothing from the Emergency,... Equipment Station (next to yard scale house) and Scott Air.Paks . for personnel protection. B. Make sure that fixed fire protection systems (deluge systems'and fire monitors) are being used to the greatest advantage. C. Provide help to block-in fuel sources by closing valves as specified by the Emergency Crew Chief. D. Perform manual fire fighting operations under the direction of the ` Emergency Crew Chief. 13. Support Group The Support Group will consist of all Maintennace, Warehouse, and Yard Personnel (Supervisors and Hourly). They will report to the Maintenance Shop and be under the orders of the Mechanical Chief. The Maintenance. Superintendent - Mechanical will stay in the shop with the personnel. The Mechanical Chief will contact him for assistance. 14. Guards A. Direct ambulance and other vehicles to the emergency scene. B. Stop all other vehicle traffic into the plant and have it park without blocking the gate. Do not permit any unauthorized personnel to enter the plant. C. Phone the Emergency Organization when instructed to do so by the Vinyl Shift Supervisor, the Compound Supervisor, or their designees. Section 1;230 Page 20 ABD00242806 FIRE PREVENTION AND EMERGENCY PLAN PAGE 21 EMERGENCY ORGANIZATION - (Continued) 14. Guards - (Continued) D. Monitor fire pump operation as noted in 11 above. E. Record wind direction and speed, barometric pressure, time and outside temperature at time of occurance if a gas release or fire has occurred. F. Announce the wind speed and direction (i.e., from , to , ) over the plant public address system if a gas release , or fire has occurred. 15. Communications Chief A. The Director of Administrative Services will act as the Communications Chief.y B. Establish the gatehouse switchboard as an emergency and communications headquarters. The Communications Chief shall also prearrange for a Secretary to act as the Switchboard Operator. Several alternates should be planned. The Switchboard Operator should be contacted immediately following receipt of the call to activate the Emergency . Organization. C. Handle all incoming and outgoing calls . EVACUATION GB WORK AREAS As noted in the IMMEDIATE ACTIONS... section of the plan, all non-essential personnel being evaucated from their work area.due to fire or large uncontrolled vapor release shall shut down the equipment for which they are responsible and proceed to the PRIMARY EVACUATION AREAS for a head count. (To expedite the head count, each department shall maintain a current list of personnel by shift grouping on a clipboard in the Supervisor's office. A listing of office personnel shall also be maintained in or near the lobby of each office area.) If conditions warrant further action to avoid danger, evacuated personnel shall proceed to the SECONDARY EVACUATION AREA, southwest of the plant guard house. In all cases, evacuated personnel must assemble by departmental grouping for a head count. In the event that: this area is unsafe, all personnel must assemble at a safe location south of Highway 25 along the north plant propetty line. Supervisors must designate non-emergency personnel to act in their place for head count purcoses if the emergency condition.requires the activation of the Emergency Crews or Emergency Organization. Wind direction at the time of a gas or vapor emergency will play an important yole in the choice of escape routes. Evacuation routes should always be at right angles to the wind (cross-wind). Use the wind socks, located on silos 415 and 231 or slurry blend tank 502 to determine the wind direction. Section 1.230 Page 21 ABD00242807 FIRE PREVENTTION AND EMERGENCY PLAN PAGE 22 PUBLIC ALERT During an emergency, Che Plant Manager, or his designee, will determine if and when action is required to protect the public, including request for Law Enforecement' Assistant. Any requests for information from reporters or other persons outside the plant including employees shall in all cases be directed to the Plant Manager or his designee. REENTRY TO WORK AREAS Personnel, except those required .to deal with the emergency condition, shall not be allowed to reenter endangered areas until the emergency condition has been corrected and verified. Upon establishment of control over VCM releases, the Shift Supervisor, equipped with Scott Air Pak and HNU Photioionizer shall verify that all areas have returned to safe levels. Whenever an employee reenters a work area in which a VCM release has occurred, for the purpose of verifying safe levels, there shall be at least two other persons equipped with Scott Air Paks observing, from a safe distance. In some cases, this may be-done by Honeywell readings. During normal office work hours, the Safety Supervisor- shall monitor public and total plant area safety with portable monitoring instruments and Scott Air Pak, if necessary. During his absence, this task shall be performed.by the Vinyl Shift Supervisor. Again, this may be done by Honeywell readings. MEDICAL TREATMENT AND SURVEILLANCE Anyone who is injured during any emergency is to be immediately treated as appropriate to circumstances. Anyone who looses consciousness because of inhalation of any substance is to be taken to the Aberdeeh-Monroe County Emergency Room as soon as possible. In all cases, the treating physician must be given the chemical name of the agent (gas) which is suspected of causing the injured person to be overcome. Medical treatment of any employees injured . by any substance will be that determined most appropriate by the Corporate Medical Division or its designee. EMERGENCY TELEPHONE NUMBERS 1. Medical Ambulance, Monroe County Hospital...................................................369-2455 Dr. Coghlan, Office................................................................................. 369-2411 Home........................................................................................ 369-4418 Dr. Turnage, Office................................................................................. 369-2413 Home........................................................................................ 369-6311 Section 1.230 Page 22 ABD00242808 FIRE PREVENTION AND EMERGENCY PLAN PAGE 23 EMERGENCY TELEPHONE NUMBERS - (Continued) 2. Police Aberdeen Police Department...................................................... 369-6454 Sheriff's Office.............................................................................. 369-2468 Mississippi State Police............................................................. (Contact 3. Fire Department Aberdeen Fire Department............................................................. 369-9551 4. Light and Water Department Aberdeen Light & Water Department....,...................,...369-4731 or..................................... 369-2159 5. Headquarters Personnel R. E. Lehmkuhl, Office................................................... (713) 965-1727 Home........................................................(713) 780-1270 R. D. Gamblin, Office Home.. (713) 965-2100 (713) 531-7242 M. S. Reynolds, Office Home.. (713) 965-2806 (713 445-9187 J. J. Hall, Office Home.. (713) 965-1709 (713) 376-8154 PoliceDept.) 6. Public Relations Personnel Houston.................................................JohnGehbauer (office),................ (713) 965-3115 (home)...................... (713) 376-9279 Lake Charles.................................... Carlton Adams (office).................. (318) 494-4215 (home)...................... (318) 477-9640 7. CHEMTREC Emergency Numbers See CHEMTREC Call Manual STORM WARNING These procedures are established to give personnel early tornado warning. When atmospheric conditions indicate that a tornado is possible: 1. The guard will continuously monitor National Weather Service broadcasts for weather reports. Section 1.230 Page 23. FIRE PREVENTION AND EMERGENCY PLA^BD00242809 PAGE 24 STORM WARNING - (Continued) 2. If the Weather Service announces a tornado watch for the area, the Guard will: ' .< A. On days - contact Plant Manager, Plant Superintendant, and all. Department Heads. B. During off-shifts and weekends - contact the Viny, Lab, and Compound Supervisors. C. Be watchful for an approahing tornado cloud. NOTE: Whenever the Vinyl Shift Supervisor is notified of an approaching severe weather system, he may direct his employees to stop charging and to initiate any other measures dictated by operating procedures to prevent the release of VCM. .. 3. If the Guard spots an approaching tornado cloud, he will call the Vinyl Control Room and ask that the tornado alert alarm, on the plant siren be sounded, and announce it over the plant P.A. system. 4. Whenever an approaching tornado cloud is announced, all personnel will take whatever action and cover that is established by departmental procedures. Section 1.230 Page 24 ABD00242810 FIRE PREVENTION AND EMERGENCY PLAN PAGE 25 . EMERGENCY ORGANIZATION CALL LIST When advised by the Shift Supervisor, or his designee, the guard will start, calling the names listed below in numerical sequence (rank order) from the appropriate list. VINYL VCM TANK FARM COMPOUND UTILITIES 1.* P. E. Markey 369-6019 2.* C. R. Miller 369-9100 3.* M. P. Blackwell 1-323-2997 4.* A. H. Sather 369-9271 5.* V. A. BeIk 369-4416 6.* J. Friend 369-7377 1.* L. D. Honeycutt 343-5595 Then call Vinyl listings. 1.* R. G. Gilreath Unlisted 2.* P. J. Kober 369-7096 3.* C. R. Miller 369-9100 4.* A. H. Sather 369-9271 5.* V.A. Belk 369-4414 6.* J. Friend 369-7377 / SWITCHBOARD OPERATOR 1.* 2.* 3.* 4;* 5.* 6.* 7i* J. L. Horstman 369-6005 F. W. Frantz 369-8508 C.. R. Snowden 1-327-7382 C. R. Miller 369-9100 A. H. Sather 369-9281 V. A. Belk 369-4416 J. Friend 369-7377 (1) Frossard, J. (2) Michels, L. (3) Pope, J. 369-6990 369-6743 Unlisted o i--i 7.* 8.* 9.* 11.* R. G. Gilreath Unlisted P. J. Kober 369-7096 J. L. Horstman 369-6005 C. R. Snowden 1-327-7382 F. W. Frantz 369-8508 7.* 8.* 9.* 10.* 11.* P. E. Markey 369-6019 M. P. Blackwell 1-323-2997 J. L. Horstman 369-6005 C. R. Snowden 1^327-7382 F. W. Frantz 369-9503 8.* 9.* 10.* 11.* P. E. Markey 369-6019 M. P. Blackwell 1- 323-2997 R. G. Gilreath Unlisted P. J. Kober 369-7096 12.* 13.* 14.* 15.* * J. G. Roberts 369-8059 J. V. Uptain 369-8109 R. W. Rye 369-4730 G. A. Morgan 369-6522;: 16.* 17.* 18. 19. R. A. Frohreich 1-327-6070 V. L. Thornhill 369-8952 W. F. Higginbotham 1-327-0827 C. E. Davis 369-8780 20. J. A. Dixon 24. A. L. Barr 369-8372 21. R. A. Miller 369-8232 25. R.D. Jacksoi 1-327-0951 256-4639 22. J. L. White 26. J.R. Willi# 369-2991 256-3810 23.* L. D. Honeycutt 27. V.E. Messic 343-5595 1-327-0741 28. D.S. Cox 369-8752 *Telephone Number Programmed into Guardhouse Telephone. Ringer. SECTION 1.230 Page 25 FIRE PREVENTION AND EMERGENCY PLAN PAGE 26 ABD00242811 >0> Q >.< O! c 3 I CO f !; aws i Mu (UoK. a a >* a rgi tH 5 S> 8 G; w QD3). *QH !'l CO 0) M CO 1: rCH u(H0 '_ . U .a o as C3 3 cm : Ctf q u ;; x '2 y r- Q.* 3! I Q -O ' 2- Q 5i-< CO '.Mat I OS > CO ;S__ X oawi ^o axc su ;| iu c as CC4aaMOJ 2 M4-JJ XtHo ii 3 hat! O3' o; i' EMERGENCY ORGANIZATION PwS ug to a' uCWO s a; X0)*1 x; ;.ICUxJ j M1 0I< rt 00 B to JS t/i Ih 0) a U. <J UO X CO CJ xa za <i x XU U (CO -M -H 3 _; zW Cb 3O CV CJ B > M OM OnS iUx) CJ U 4c3 >- M Out CJ X Z CJ >--i M U >*M O C-H 03 *HX W >CO x . c; X3w SW fXci---I' U S3O! <h 3:I co x; t-c ! to CJ| CO 1 C0HM) WhO 4OJ O Z >U-H.'. XU h->Ma0U) S< H-JHJ: 3 OJ O MS' a a a) M 3 CM h CJ to 0H1 Qh 4>). Xh UNO B! ------ -----ABD00242812 ......... FIRE PREVENTION AND EMERGENCY PLAN PAGE.27 PLANT EMERGENCY ALARM DATA SHEET DATE: ALARM: (Circle One) Fire Vapor TIME: Evacuation* Tornado** * Evacuation alarm must follow either the fire or vapor alarm. ** The tornado alarm and the evacuation alarm are the same alarm, The difference lies in the fact that the evacuation alarm by itself means a tornado is approaching. The evacuation alarm must be proceeded by either the fire or vapor alarm. LOCATION: _____________________ SPECIFIC NATURE OF PROBLEM V Alarm Activated By: Section 1.230 Page 27 ---- ~ -A`BD00242813 -- ABERDEEN CHEMICAL PLANT FIRE REPORT PART ! (To be filled in by Supervisor of area or activity involved) Date of Fire: Time: A.M. -P.M. Exact location of fire: Equipment involved (tank no., pump no., name of bldg., etc.) How did the fire start? How was the fire put out? Description of personnel injuries: Description of property damage: What immediate action have you taken to prevent a recurrence? Was fire protection adequate? ___________________j_____________________________ _ Estimate of damage: (A) 0 - $1000 (B) $1000-$15,000 . (C) $15,000 + Production delays: __________________________________________________________________ Signed Date ' ' (Supervisor) _______ SignedDate (Dept. Head) PART II. (Safety Department Review) * Remarks: ________________________________________________________________________________ Signed :Date (Safety Director) PART III. Remarks: (Management Review) Signed (Plant Supt.) Date RETURN TO SAFETY DEPARTMENT Signed (Plant Mgr,) Date ABD00242814 E. PHOTOGRAPHS FIG. 2 - VIEW OF HANDBRAKE LOCATED AT THE END OF TANKCAR ABD00242815 FIG. 3 - UNLOADING ARRANGEMENT FOR VCM TANKCARS ABD00242816 TO BULLETS COMPRESSOR #4 LIQUID VAPOR LINE COMPRESSOR #5 LIQUID VAPOR LINE COMPRESSOR #3 LIQUID/VAPOR LINE . nCOMPRESSOR LIQUID/VAPOR LINE -------------#1 SIGHT GLASS LINE ------- #2 SIGHT GLASS LINE #3 SIGHT GLASS LINE FIG. 4 - PIPING AND VALVES ON WEST SIDE.OF THE COMPRESSOR SHED ABD00242817 FIG. 5 - SIGHT GLASSES FOR CHECKING VCM LIQUID UNLOADING, LOCATED ON EAST SIDE- OF COMPRESSOR SHED SEEN LOOKING NORTHWARD ABD00242818 FIG. 7 - T (201) EMISSION RECOVERY SYSTEM KNOCKOUT POTNORTHWEST CORNER OF COMPRESSOR SHED OF COMPRESSOR SHED rm c a r.n mi?r tra f ia m m a b l EGAS ABD002428^9 . \ ABD00242820 11 . -i *^r * 5